fuse CHRYSLER VOYAGER 2001 Service Manual

Symptom:
*ENGINE CRANKS DOES NOT START
POSSIBLE CAUSES
FUEL PUMP RELAY
NO START PRE-TEST
POWERTRAIN FUSES OPEN
FUEL PRESSURE OUT OF SPECS
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
FUEL PUMP CAPACITY (VOLUME) OUT OF SPECS
FUEL PUMP RELAY FUSED B+ CIRCUIT
OTHER POSSIBLE CAUSES FOR NO START
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN/HIGH RESISTANCE
IPM FUSE & RELAY CENTER
FUEL PUMP MODULE
TEST ACTION APPLICABILITY
1Note: The following list of items must be checked before continuing with
any no start tests.
The battery must be fully charged and in good condition. A low charged battery may
produce invalid test results. If the battery is low, charge the battery and then attempt
to start the vehicle by cranking the engine for 15 seconds, 3 consecutive times.
This will allow any DTC's to set that may have been erased due to a dead battery.
Ensure the Powers and Ground to the PCM are ok.
Make sure the PCM communicates with the DRB and that there are no DTC's stored
in the PCM memory. If the PCM reports a No Response condition, refer to the
Communication category for the proper tests.
Read the PCM DTC's with the DRB. If any DTC's are present, they must be repaired
before continuing with any other No Start diagnostic tests. Refer to the Symptom list
for the related P-code that is reported by the PCM.
Ensure that the PCI bus is functional. Attempt to communicate with the Instrument
Cluster and SKIM, If you are unable to establish communicate refer to the
Communication category for the proper symptoms.
The Sentry Key Immobilizer System must be operating properly. Check for proper
communication with the DRB and check for DTC's that may be stored in the Sentry
Key Immobilizer Module (SKIM). repair the DTC(s) before continuing.
If no DTC's are found, using the DRB select Clear PCM (Batt Disconnect).
Crank the engine several times. Using the DRB, read DTC's. If a DTC is present
perform the DTC diagnostics before continuing.
Were any problems found?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Go To 2
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TEST ACTION APPLICABILITY
2 Check for any open fuses in the IPM that may be related to the No Start condition.
Are any of the fuses open?All
Ye s®Using the wiring diagram/schematic as a guide, inspect the
wiring and connectors, repair as necessary. Replace the Fuse.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Go To 3
3 Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Note: It may be necessary to use a mechanics stethoscope in the next step.
Listen for fuel pump operation at the fuel tank.
Does the Fuel Pump operate?All
Ye s®Go To 4
No®Go To 9
Caution: Stop All Actuations.
4 Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install a fuel pressure gauge to the fuel rail test port.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 kPa +/- 34 kPa (58 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.All
Below Specification
Go To 5
Within Specification
Go To 7
Above Specification
Replace the fuel filter/fuel pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER-1.
Caution: Stop All Actuations.
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*ENGINE CRANKS DOES NOT START ÐContinued

TEST ACTION APPLICABILITY
8 The following items need to be checked as a possible cause for a no start condition.
Refer to any Technical Service Bulletins that may apply to the symptom.
The spark plugs must be free from fuel, oil, coolant and/or any foreign material or
deposits.
The fuel must be free from contamination.
The exhaust may be free from restrictions.
The engine compression must be within specifications.
The engine valve timing must be within specifications.
The engine must be free from vacuum leaks.
Were any of the above conditions found?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Test Complete.
9 Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Using a 12 volt test light connected to ground, probe the Fuel Pump Relay Output
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 10
No®Go To 12
Caution: Stop All Actuations.
10 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Note: Check connectors - It is critical that the connector is free from any
signs of corrosion or deformities - Clean/repair as necessary.
Using a test light connected to battery voltage, probe the Fuel Pump ground circuit
at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 11
No®Repair the open/high resistance in the fuel pump ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
11 If there are no possible causes remaining, view repair. All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
12 Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
With a 12 volt test light connected to ground, probe the Fuel Pump Relay Fused B+
circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 13
No®Check for an open Fuel Pump fuse, repair cause of open. If OK,
replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
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*ENGINE CRANKS DOES NOT START ÐContinued

TEST ACTION APPLICABILITY
13 Turn the ignition off.
Disconnect the IPM C8 harness connector.
Disconnect the Fuel Pump Module harness connector.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM
harness connector and the Fuel Pump Module connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 14
No®Repair the open fuel pump relay output circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
14NOTE: Ensure all IPM harness connector are connected.
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Remove the Fuel Pump Relay from the IPM.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM and
the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the Fuel Pump Relay.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
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*ENGINE CRANKS DOES NOT START ÐContinued

Symptom:
*NO CRANK CONDITION
POSSIBLE CAUSES
REPAIR MECHANICAL CONDITION
TRANSMISSION RANGE SENSOR
BATTERY CIRCUIT RESISTANCE TOO HIGH
IGNITION SWITCH OUTPUT CIRCUIT OPEN
STARTER RELAY CONTROL CIRCUIT OPEN
STARTER RELAY OUTPUT CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
STARTER
STARTER MOTOR RELAY
STARTER RELAY
TEST ACTION APPLICABILITY
1WARNING: MAKE SURE THE BATTERY IS DISCONNECTED, THEN WAIT
TWO MINUTES BEFORE PROCEEDING.
Turn the engine over by hand to ensure the engine is not seized.
Is the engine able to turn over?All
Ye s®Go To 2
No®Repair the mechanical condition preventing the starter motor
from cranking.
Perform POWERTRAIN VERIFICATION TEST VER-1.
2 Turn the ignition off.
Disconnect the PCM harness connectors.
Move the Gear selector through all gear positions, from Park to 1st and back.
While moving the gear selector through each gear, measure the resistance between
ground and the P/N Position Switch Sense circuit.
Did the resistance change from above 10.0 ohms to below 10.0 ohms?All
Ye s®Go To 3
No®Replace the Transmission Range Sensor.
Perform POWERTRAIN VERIFICATION TEST VER-1.
3 Turn the ignition off.
Check the Battery Cables for high resistance using the service information proce-
dure.
Did either Battery Cable have a voltage drop greater than 0.2 volt?All
Ye s®Repair the Battery circuit for high resistance.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Go To 4
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TEST ACTION APPLICABILITY
8 Turn ignition off.
Remove the Starter Relay from the PDC.
Disconnect the Starter Relay Output connector from the Starter Solenoid.
Measure the resistance of the Starter Relay Output circuit between the Relay and the
Solenoid harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 9
No®Repair Starter Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER-1.
9 Turn the ignition off.
Remove the Starter Relay from the PDC.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit at the
Starter Relay terminal.
Does the test light illuminate brightly?All
Ye s®Go To 10
No®Repair the Fused B(+) Circuit for an open or high resistance.
Perform POWERTRAIN VERIFICATION TEST VER-1.
10 If there are no other possible causes remaining, review repair. All
Repair
Replace the Starter.
Perform POWERTRAIN VERIFICATION TEST VER-1.
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*NO CRANK CONDITION ÐContinued

Symptom:
*NO RESPONSE FROM PCM WITH A NO START CONDITION
POSSIBLE CAUSES
PCM FUSED B+ CIRCUIT
PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT
PCM GROUND CIRCUITS
PCM
TEST ACTION APPLICABILITY
1NOTE: The DRBIIItand cable must be operating properly for the results of
this test to be valid.
NOTE: Ensure the ignition switch was on when trying to communicate with
the PCM.
Turn the ignition off.
Disconnect the PCM harness connector.
Using a 12-volt test light connected to ground, probe the PCM Fused B+ circuit in the
PCM harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 2
No®Repair the Fused B+ circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
2 Turn the ignition off.
Disconnect the PCM harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the PCM Fused Ignition Switch
Output circuit in the PCM harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Repair the Ignition Switch Output circuit
Perform POWERTRAIN VERIFICATION TEST VER-1.
3 Turn the ignition off.
Disconnect the PCM harness connector.
Using a 12-volt test light connected to battery voltage, probe the PCM ground circuits
in the PCM harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 4
No®Repair the PCM ground circuits.
Perform POWERTRAIN VERIFICATION TEST VER-1.
4 If there is no possible causes remaining, view repair. All
Repair
Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER-1.
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8.0 COMPONENT LOCATIONS
8.1 CONTROL MODULES AND FUSE & RELAY CENTER
8.2 CONTROLS AND SOLENOID
2.4L3.3L/3.8L
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COMPONENT LOCATIONS

AMBIENT TEMPERATURE SENSOR (SENSOR SIDE)-2WAYCAV CIRCUIT FUNCTION
1 - AMBIENT TEMPERATURE SENSOR SIGNAL
2 - AMBIENT TEMPERATURE SENSOR RETURN
BRAKE LAMP SWITCH - BLACK 6 WAYCAV CIRCUIT FUNCTION
1 A103 18GY/RD FUSED B(+)
2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
3 V30 20VT/WT SPEED CONTROL BRAKE SWITCH OUTPUT
4 V32 20VT/YL SPEED CONTROL ON/OFF SWITCH SENSE
5 Z429 20BK/OR GROUND
6 B29 20DG/WT BRAKE SWITCH SENSE
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL
2 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
CAMSHAFT POSITION SENSOR - BLACK 3 WAYCAV CIRCUIT FUNCTION
1 F888 18BR/PK 8 VOLT SUPPLY
2 K900 18DB/DG SENSOR GROUND
3 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL
CLOCKSPRING C1 - WHITE 6 WAYCAV CIRCUIT FUNCTION
1 X920 20GY/OR (AUTOMAT-
IC TEMPERATURE CON-
TROL)RADIO CONTROL MUX RETURN
2 X20 20GY/WT (AUTOMAT-
IC TEMPERATURE CON-
TROL)RADIO CONTROL MUX
3 X3 20DG/VT HORN SWITCH SENSE
4 V37 20VT SPEED CONTROL SWITCH SIGNAL
5 Z23 20BK/LB GROUND
6- -
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CONNECTOR PINOUTS

CRANKSHAFT POSITION SENSOR - BLACK 3 WAYCAV CIRCUIT FUNCTION
1 F888 18BR/PK 8 VOLT SUPPLY
2 K900 18DB/DG SENSOR GROUND
3 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
DATA LINK CONNECTOR - WHITE 16 WAYCAV CIRCUIT FUNCTION
1- -
2 D25 20WT/VT PCI BUS
3- -
4 Z11 18BK/LG GROUND
5 Z111 18BK/WT GROUND
6 D20 20WT/LG SCI RECEIVE
7 D21 20WT/BR SCI TRANSMIT
8- -
9 D23 20WT/BR FLASH PROGRAM ENABLE
10 - -
11 - -
12 - -
13 - -
14 D16 20WT/OR SCI RECEIVE
15 - -
16 A105 20DB/RD FUSED B(+)
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAYCAV CIRCUIT FUNCTION
1 D25 20WT/VT PCI BUS (PCM/SKIM)
2 D25 20WT/VT PCI BUS (HVAC)
3 D25 20WT/VT PCI BUS (RADIO)
4 D25 20WT/VT PCI BUS (ORC)
5 D25 20WT/VT PCI BUS (CLUSTER)
6 D25 20WT/VT PCI BUS (BCM)
7 D25 20WT/VT PCI BUS (DLC)
8 D25 20WT/VT PCI BUS (OVERHEAD CONSOLE)
9 D25 20WT/VT PCI BUS (IPM)
10 D25 20WT/VT PCI BUS (LSIACM)
11 D25 20WT/VT PCI BUS (MEMORY SEAT/MIRROR)
12 D25 20WT/VT PCI BUS (PWR DOOR/ LT, RT LIFTGATE)
13 D25 20WT/VT PCI BUS (RSIACM)
14 - -
15 - -
16 - -
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CONNECTOR PINOUTS