diesel CHRYSLER VOYAGER 2001 Owner's Manual

Symptom:
*ANY PCI BUS INDICATOR INOPERATIVE
POSSIBLE CAUSES
NO RESPONSE - PCI BUS
NO RESPONSE - INSTRUMENT CLUSTER
NO RESPONSE - ECM / PCM
INDICATOR INOPERATIVE
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, select J1850 Module Scan.
Does the DRBIIItdisplay MIC PRESENT on the BUS?All
Ye s®Go To 2
No®Refer to the COMMUNICATION category and perform the ap-
propriate symptom.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition on.
With the DRBIIIt, Select Body, MIC, the MODULE DISPLAY.
Does the DRBIIItdisplay NO RESPONSE from MIC?All
Ye s®Refer to the symptom list for problems related to *NO RE-
SPONSE FROM THE INSTRUMENT CLUSTER.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 3
3 Turn the ignition on.
With the DRBIIIt, select Body, MIC, SYSTEM TESTS, PCM MONITOR.
Does the DRBIIItdisplay PCM INACTIVE on the BUS?All
Ye s®Refer to the symptom list for problems related to *NO RE-
SPONSE FROM THE POWERTRAIN CONTROL MODULE
(Gas) / or *NO RESPONSE FROM THE ENGINE CONTROL
MODULE (Diesel)
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 4
4NOTE: Diagnose and repair any PCM (gas) or ECM (diesel) DTCs before
proceeding with this test.
Perform the Instrument Cluster diagnostic Self Test.
Observe the indicator in question during the Self Test.
Did the indicator illuminate?All
Ye s®Refer to the appropriate Servic Information category to diagnose
the related system.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the Instrument Cluster in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
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INSTRUMENT CLUSTER

Symptom:
OTIS MODULE MESSAGE MISMATCH (DIESEL)
When Monitored and Set Condition:
OTIS MODULE MESSAGE MISMATCH (DIESEL)
When Monitored: With the ignition on.
Set Condition: FCM has learned EC Mirror but the vehicle is Not equipped with EC
Mirror.
POSSIBLE CAUSES
INTERMITTENT CONDITION
CMTC/EVIC COMMUNICATION
CMTC/EVIC MODULE
FRONT CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: All communication DTC(s) that may have set along with this DTC
must diagnosed before continuing.
NOTE: If the DTC EC Mirror Day/Night Line Fault is present in the EVIC
along with this DTC, diagnose the EC Mirror Day/Night Line Fault first
before continuing.
With the DRBIIIt, erase the DTC.
Cycle the ignition on and off several times, leaving the ignition on for at least 15
seconds.
With the DRBIIIt, read DTCs.
Did the DTC OTIS Module Message Mismatch reset?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition on.
With the DRBIIIt, attempt to communicate with the CMTC/EVIC Module.
Can communication be established with the CMTC/EVIC Module?All
Ye s®Go To 3
No®Refer to the Communication Category and perform the appropri-
ate symptom.
Perform BODY VERIFICATION TEST - VER 1.
717
OVERHEAD CONSOLE

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Install a substitute CMTC/EVIC Module in place of the original module.
With the DRBIIIt, erase DTCs.
Turn the ignition on.
Cycle the ignition on and off, leaving the ignition in the on position for at least 15
seconds each time.
With the DRBIIIt, read DTCs.
Did the DTC reset?All
Ye s®Replace the Front Control Module.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the CMTC/EVIC Module.
Perform BODY VERIFICATION TEST - VER 1.
4WARNING: 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.
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.
718
OVERHEAD CONSOLE
OTIS MODULE MESSAGE MISMATCH (DIESEL) ÐContinued

CABIN HEATER VERIFICATION TEST - VER 1 APPLICABILITY
1. 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 FOL-
LOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH.
2. WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORMING A
COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
3. NOTE: The DCHA Control will store up to three DTCs in its memory.
4. 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.
5. 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 occurrence.
6. Verify that the vehicle's battery is fully charged.
7. Verify that there is more than 1/8 of a tank of fuel in the vehicle's fuel tank. Add fuel, if
necessary.
8. Verify that all DCHA coolant hoses and fuel lines are securely fastened to their respective
components.
9. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
10. If a heater installation/cooling system service was performed, purge the coolant circuit of
air in accordance with the Service Information.
11. Turn the ignition on.
12. Set the Blend Control to the max cool position.
13. Ensure that all accessories are turned off.
14. If a fuel system service requiring fuel to drain out of the DCHA fuel line was performed,
prime the DCHA Dosing Pump in accordance with the Service Information.
15. With the DRBIIIt, record and erase all DTCs from the Diesel Cabin Heater Assist (DCHA)
Control and the Front Control Module (FCM). Cycle the ignition off then on.
16. Start the engine.
17. Allow the engine to idle.
18. Turn the A/C - Heater Control Module's Power switch on.
19. Turn the Blower switch to the high speed position.
20. 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.
21. 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.
22. NOTE: While performing the Diesel Cabin Heater Test, inspect the coolant and
fuel connections for leakage.
23. With the DRBIIItin HVAC, Systems Tests, select Diesel Cabin Heater Test and press #1.
24. Set the Blend Control to the max heat position. Allow the Diesel Cabin Heater Test to run
for five minutes. Upon completion of the test, proceed as follows:
25. Set the Blend Control to the max cool position.
26. Press #2 on the DRBIIItkeyboard.
27. Turn the Blower switch off.
28. Turn the A/C - Heater Control Module's Power switch off.
29. Turn the ignition off, wait 5 seconds, then turn the ignition on.
30. Using the DRBIIIt, read the Cabin Heater and Active FCM DTCs.
Are any DTC's present or is the original condition still present?All
Ye s®Repair is not complete, refer to the appropriate symptom.
No®Repair is complete.
991
VERIFICATION TESTS
Verification Tests ÐContinued

ROAD TEST VERIFICATION - VER-2 APPLICABILITY
1. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and
4.
3. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom
no longer exists, the repair was successful and testing is now complete.
4. If the initial or another symptom exists, the repair is not complete. Check all pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List if necessary.
5. For previously read DTCs that have not been dealt with, return to the Symptom List and
follow the diagnostic path for that DTC; otherwise, continue.
6. If the Engine Control Module (ECM) (diesel only) or Powertrain Control Module (PCM) has
not been changed, perform steps 7 and 8, otherwise, continue with step 9.
7. With the DRB, erase all diagnostic trouble codes (DTCs), then disconnect the DRB.
8. Turn the ignition off for at least 10 seconds.
9. Ensure no DTCs remain by performing steps 10 through 13.
10. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test
is for an A/C Relay Control Circuit, drive the vehicle for at least 5 minutes with the A/C on.
11. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart
the engine and continue.
12. Upon completion of the road test, turn the engine off and check for DTCs with the DRB.
13. If the repaired DTC has reset, the repair is not complete. Check for any pertinent Technical
Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the repair was
successful and is now complete.
Are any DTCs or symptoms remaining?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
SKIS VERIFICATION APPLICABILITY
1. Reconnect all previously disconnected components and connectors.
2. Obtain the vehicle's unique Personal Identification Number (PIN) assigned to it's original
SKIM. This number can be obtained from the vehicle's invoice or Chrysler's Customer Center
(1-800-992-1997).
3. NOTE: When entering the PIN, care should be taken because the SKIM will only
allow 3 consecutive attempts to enter the correct PIN. If 3 consecutive incorrect
PIN's are entered the SKIM will Lock Out the DRB III for 1 hour.
4. To exit Lock Out mode, the ignition key must remain in the Run position continually for 1
hour. Turn off all accessories and connect a battery charger if necessary.
5. With the DRB III, select Theft Alarm, SKIM and Miscellaneous. Then select desired
procedure and follow the steps that will be displayed.
6. If the SKIM has been replaced, ensure all of the vehicle ignition keys are programmed to the
new SKIM.
7. NOTE: Prior to returning vehicle to the costumer, perform a module scan to be
sure that all DTC's are erased. Erase any DTC's that are found.
8. With the DRB III erase all DTC's. Perform 5 ignition key cycles leaving the key on for at least
90 seconds per cycle.
9. With the DRB III, read the SKIM DTC's.
Are there any SKIM DTC's?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
993
VERIFICATION TESTS
Verification Tests ÐContinued

8.5 CABIN HEATER
8.5.1 DIESEL CABIN HEATER ASSIST (CABIN HEATER) ASSEMBLY
8.5.2 C331 CONNECTOR
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1001
COMPONENT LOCATIONS

C327 - YELLOW (SAFETY SEAT SIDE)CAV CIRCUIT
1-
2-
3 R34 18LB/WT (EXCEPT
BUILT-UP-EXPORT)
3 R34 18WT/BK (BUILT-UP-
EXPORT)
4 R32 18DG/WT (BUILT-UP-
EXPORT)
4 R32 18LB/OR (EXCEPT
BUILT-UP-EXPORT)
C327 - YELLOW (SEAT SIDE)CAV CIRCUIT
1-
2-
3 R34 18LB/WT
4 R32 18LB/OR
C330 (DIESEL) - GRAY (CABIN HEATER JUMPER SIDE)CAV CIRCUIT
1 A119 16RD/OR
2 C41 20LB/DG
3 D21 20WT
4 Z149 16BK/DB
C330 (DIESEL) - LT. GRAY (BODY SIDE)CAV CIRCUIT
1 A119 16RD/OR
2 C41 20LB/DG
3 D21 20WT/BR
4 Z149 16BK/DB
C331 (DIESEL) - BLACK (CABIN HEATER JUMPER SIDE)CAV CIRCUIT
1 A119 16RD/OR
2 C41 20LB/DG
3 D21 20WT
4 Z149 18BK/DB
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CONNECTOR PINOUTS

C331 (DIESEL) - GRAY (CABIN HEATED COMPONENT SIDE)CAV CIRCUIT
1 A119 14RD/OR
2 C41 20DB/OR
3 D21 20WT/DB
4 Z149 14BK/DB
CABIN HEATER ASSIST C1 (DIESEL) - BLACK 6 WAYCAV CIRCUIT FUNCTION
1- -
2 D21 20WT/DB SCI TRANSMIT
3- -
4- -
5 C41 20DB/OR CABIN HEATER ASSIST CONTROL
6 18RD DOSING PUMP CONTROL
CABIN HEATER ASSIST C2 (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 A119 14RD/OR FUSED B(+)
2 Z149 14BK/DB GROUND
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1032
CONNECTOR PINOUTS

ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAYCAV CIRCUIT FUNCTION
1 Z130 14BK/BR GROUND
2 Z131 14BK/DG GROUND
3 K20 14BR/GY GENERATOR FIELD CONTROL
4 K342 14BR/WT ECM/PCM RELAY OUTPUT
5 K342 14BR/WT ECM/PCM RELAY OUTPUT
6- -
7 D25 20WT/VT PCI BUS
8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND
9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
16 K80 20DB/TN FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 N1 20DB/OR FUEL HEATER RELAY OUTPUT
20 Z138 20BK/OR GROUND
21 K900 20DB/DG SENSOR GROUND
22 F202 20PK/GY IGNITION SWITCH OUTPUT (RUN-START)
23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B
24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
25 - -
26 - -
27 - -
28 - -
29 - -
30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL
32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL
33 - -
34 K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
35 K853 20DB/BR ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY
36 C18 20LB/BR A/C PRESSURE SENSOR SIGNAL
37 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL
38 V37 20VT/TN SPEED CONTROL SWITCH SIGNAL
39 - -
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Z122 18WT GROUND (DRAIN)
43 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
44 - -
45 - -
46 - -
47 L50 20WT/TN PRIMARY BRAKE SWITCH SIGNAL
48 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
49 T751 20YL IGNITION SWITCH OUTPUT (START)
50 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
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CONNECTOR PINOUTS

ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY - CONTINUEDCAV CIRCUIT FUNCTION
51 - -
52 K121 20DB BOOST PRESSURE SENSOR GROUND
53 - -
54 K957 20BK/OR MASS AIR FLOW SENSOR GROUND
55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 - -
58 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND
59 - -
60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20BR/WT ECM/PCM RELAY CONTROL
62 - -
63 D21 20WT/BR SCI TRANSMIT
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
67 - -
68 - -
69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
71 - -
72 N21 20DB/TN LIFT PUMP RELAY CONTROL
73 - -
74 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
75 - -
76 - -
77 K152 20DB/WT GLOW PLUG RELAY CONTROL
78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
79 - -
80 K87 20BR FUEL PRESSURE SOLENOID CONTROL
81 K87 20BR FUEL PRESSURE SOLENOID CONTROL
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1040
CONNECTOR PINOUTS