relay CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Fuel Pump Relay Control circuit between the
Intelligent Power Module C3 harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 8
No®Repair the Fuel Pump Relay Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
8 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Fuel Pump Relay Control circuit in the Intelligent
Power Module C3 harness connector to ground.
Is the resistance below 5.0 ohms.All
Ye s®Repair the Fuel Pump Relay Control circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 9
9 If there are 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 - 5.
10 Turn the ignition off.
Disconnect the Intelligent Power Module C9 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM harness connector.
Does the test light illuminate?All
Ye s®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
183
DRIVEABILITY - GAS
P1282-FUEL PUMP RELAY CONTROL CIRCUIT ÐContinued

Symptom:
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Monitored: With ignition on. Battery voltage above 10 volts.
Set Condition: An open or shorted condition is detected in the ASD relay control circuit.
POSSIBLE CAUSES
ASD RELAY INTERMITTENT OPERATION
INTERMITTENT CONDITION
FUSED B+ OUTPUT CIRCUIT
ASD RELAY
IPM FUSE & RELAY CENTER
ASD RELAY CONTROL CIRCUIT OPEN
ASD RELAY CONTROL CIRCUIT SHORT TO GROUND
PCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, actuate the ASD Relay.
Is the ASD Relay operating?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition on.
With the DRBIIIt, actuate the ASD Relay.
Wiggle the wiring harness from the ASD Relay to the PCM while the relay is
actuating.
Did the ASD Relay stop when wiggling the wiring harness?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
195
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3WARNING: 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 DRB Freeze Frame information. 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 POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
4NOTE: Inspect the ASD Relay fuse located in the IPM. If the ASD Relay fuse
is open, repair the cause of the open first before continuing. Inspect the ASD
Relay Output circuit for a short to ground for the cause of the open fuse.
Turn the ignition off.
Remove the ASD Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 5
No®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5 Turn the ignition off.
Remove the ASD Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the ASD Relay Control circuit
in the IPM.
With the DRBIIIt, actuate the ASD Relay.
Does the test light flash on and off?All
Ye s®Replace the ASD Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 6
6 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the ASD Relay Control circuit
in the IPM harness connector.
With the DRBIIIt, actuate the ASD Relay.
Does the test light flash on and off?All
Ye s®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 7
196
DRIVEABILITY - GAS
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the ASD Relay Control circuit between the Intelligent
Power Module C3 harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 8
No®Repair the ASD Relay Control circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
8 Turn the ignition off.
Disconnect the Intelligent Power Module C3 harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the ASD Relay Control circuit in the Intelligent Power
Module C3 harness connector to ground.
Is the resistance below 5.0 ohms.All
Ye s®Repair the ASD Relay Control circuit for a short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 9
9 If there are 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 - 5.
197
DRIVEABILITY - GAS
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT ÐContinued

Symptom:
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Monitored and Set Condition:
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Monitored: With ignition key on. Battery voltage greater than 10 volts.
Set Condition: No voltage sensed at the PCM when the ASD relay is energized.
POSSIBLE CAUSES
INTERMITTENT CONDITION
ASD RELAY
FUSED B+ CIRCUIT
ASD RELAY OUTPUT CIRCUIT OPEN (NO START)
IPM FUSE & RELAY CENTER
ASD RELAY OUTPUT CIRCUIT OPEN
PCM START
PCM
TEST ACTION APPLICABILITY
1NOTE: Inspect the ASD Relay fuse located in the IPM. If the ASD Relay fuse
is open, repair the cause of the open first before continuing. Inspect the ASD
Relay Output circuit for a short to ground for the cause of the open fuse.
NOTE: Diagnose P1388 - Auto Shutdown Relay Control Circuit first if set
along with this DTC.
With the DRBIIIt, erase the DTC.
Attempt to start the engine. If the engine will not start, crank the engine for at least
15 seconds. It may be necessary to repeat several times.
Does the DTC reset.All
Ye s®Go To 2
No®Go To 9
2 Attempt to start the engine.
Does the engine start.All
Ye s®Go To 3
No®Go To 5
198
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the IPM C4 harness connector
Measure the resistance of the ASD Output circuit between the IPM harness
connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 4
No®Repair the ASD Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
4 If there are 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 - 5.
5 Turn the ignition off.
Install a substitute relay in place of the ASD Relay.
Attempt to start the engine.
With the DRBIIIt, read DTCs.
Does the DTC reset?All
Ye s®Go To 6
No®Replace the ASD Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6 Turn the ignition off.
Remove the ASD Relay from the IPM.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 7
No®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
7 Turn the ignition off.
Remove the ASD Relay from the IPM.
Disconnect the PCM harness connector.
Disconnect the IPM C4 harness connector.
Measure the resistance of the ASD Relay Output circuit between the IPM harness
connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 8
No®Repair the ASD Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
199
DRIVEABILITY - GAS
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM ÐContinued

TEST ACTION APPLICABILITY
8NOTE: Ensure the IPM C4 harness connector is connected to the IPM.
Turn the ignition off.
Disconnect the PCM harness connector.
Measure the resistance of the ASD Relay Output circuit between the IPM and the
PCM harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9WARNING: 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. Check for the
engine stumble, stall or quite running.
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 POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
200
DRIVEABILITY - GAS
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM ÐContinued

Symptom:
P1491-RAD FAN CONTROL RELAY CIRCUIT
When Monitored and Set Condition:
P1491-RAD FAN CONTROL RELAY CIRCUIT
When Monitored: With the ignition on. Battery voltage greater than 10 volts.
Set Condition: An open or shorted circuit is detected in the radiator fan relay control
circuit.
POSSIBLE CAUSES
RADIATOR FAN RELAY INTERMITTENT OPERATION
INTERMITTENT CONDITION
GROUND CIRCUIT
FUSED B+ OUTPUT CIRCUIT
POWERTRAIN CONTROL MODULE
RADIATOR FAN RELAY CONTROL CIRCUIT SHORT TO GROUND
RADIATOR FAN RELAY CONTROL CIRCUIT OPEN (IPM)
RADIATOR FAN RELAY CONTROL CIRCUIT OPEN (PCM)
RADIATOR FAN RELAY CONTROL CIRCUIT SHORTED TO GROUND (IPM)
RADIATOR FAN RELAY CONTROL CIRCUIT SHORT TO GROUND (PCM)
INTELLIGENT POWER MODULE (OPEN)
INTELLIGENT POWER MODULE (SHORTED)
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, actuate the Radiator Fan Relay.
Are both Radiator Fan operating?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition on.
With the DRBIIIt, actuate the Radiator Fan Relay.
Wiggle the wiring harness from the Radiator Fan Relay to the PCM while the relay
is actuating.
Did the Radiator Fan Relay stop when wiggling the wiring harness?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
210
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3WARNING: 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 DRB Freeze Frame information. 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 POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
4 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Using a 12-volt test light connected to 12-volts, probe the Ground circuit in the
Radiator Fan Relay harness connector.
Does the test light illuminate?All
Ye s®Go To 5
No®Repair the Ground circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5NOTE: Inspect the Radiator Fan fuse located in the IPM.
Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Measure the voltage of the Fused B+ Output circuit in the Radiator Fan Relay
harness connector.
Is the voltage above 11.0 volts?All
Ye s®Go To 6
No®Repair the Fused B+ circuit. Check and replace any open fuses.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6NOTE: Ensure the Radiator Fan Relay harness connector is connected.
Turn the ignition off.
Disconnect the PCM harness connector.
Turn the ignition on.
Using a jumper wire, momentarily jumper the Radiator Fan Relay Control circuit to
ground.
Did the Radiator Fans operate?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 7
211
DRIVEABILITY - GAS
P1491-RAD FAN CONTROL RELAY CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit between the
Radiator Fan Relay harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Go To 11
8 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit in the Radiator Fan
Relay harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Go To 9
No®Replace Radiator Fan Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the IPM C2 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit in the Radiator Fan
Relay harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Radiator Fan Relay Control circuit for a short to
ground between the Radiator Fan Relay harness connector and
the IPM harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 10
10 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the IPM C3 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit in the PCM harness
connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Radiator Fan Relay Control circuit for a short to
ground between PCM harness connector and the IPM harness
connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
212
DRIVEABILITY - GAS
P1491-RAD FAN CONTROL RELAY CIRCUIT ÐContinued