light CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
9 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 at the IPM.
Does the test light illuminate?All
Ye s®Go To 10
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.
10 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Disconnect the IPM C8 harness connector.
Measure the resistance of the Fuel Pump Relay Output circuit from between the IPM
harness connector and the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 11
No®Repair the Fuel Pump Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER-1.
11NOTE: Ensure all IPM harness connectors 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.
230
DRIVEABILITY - GAS
*CHECKING FUEL DELIVERY ÐContinued

Symptom:
*CHECKING PCM POWER AND GROUND CIRCUITS
POSSIBLE CAUSES
PCM FUSED B+ CIRCUIT
PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT
PCM GROUND CIRCUITS
TEST ACTION APPLICABILITY
1 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®Test Complete.
No®Repair the PCM ground circuits.
Perform POWERTRAIN VERIFICATION TEST VER-1.
234
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Remove the A/C Clutch 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 brightly?All
Ye s®Go To 5
No®Check for an open A/C Clutch fuse, repair the cause of the open
fuse. If OK, replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
5 Turn the ignition off.
Disconnect the IPM C3 harness connector.
Disconnect the A/C Clutch harness connector.
Measure the resistance of the A/C Clutch Relay Output circuit between the IPM
harness connector and the A/C Clutch harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the A/C Clutch Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
6NOTE: Ensure all IPM harness connectors are connected.
Turn the ignition off.
Disconnect the A/C Clutch harness connector.
Remove the A/C Clutch Relay from the IPM.
Measure the resistance of the A/C Clutch Relay Output circuit between the IPM and
the A/C Clutch harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the A/C Clutch Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
237
DRIVEABILITY - GAS
*CHECKING THE A/C RELAY OUTPUT ÐContinued

TEST ACTION APPLICABILITY
3WARNING: KEEP CLEAR OF THE ENGINE'S MOVING PARTS.
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.
Remove the A/C Clutch Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit in the IPM.
Does the test light illuminate?All
Ye s®Go To 5
No®Go To 10
5 Turn the ignition off.
Remove the A/C Clutch Relay from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, probe the A/C Clutch Relay circuit in
the IPM.
With the DRBIIIt, actuate the A/C Clutch Relay.
Does the test light flash on and off?All
Ye s®Replace the A/C Clutch 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 A/C Clutch Relay Control
circuit in the IPM harness connector.
With the DRBIIIt, actuate the A/C Clutch 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
240
HEATING & A/C
P0645-A/C CLUTCH RELAY CKT 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 A/C Clutch 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 A/C Clutch 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 A/C Clutch 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 Module in
accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
10 Turn the ignition off.
Disconnect the Intelligent Power Module C3 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.
241
HEATING & A/C
P0645-A/C CLUTCH RELAY CKT ÐContinued

TEST ACTION APPLICABILITY
1 Turn the ignition on.
NOTE: In the below step you will need to actuate both S/C solenoids
separately. Note the operation of the each solenoid when actuated.
With the DRBIIIt, actuate the Speed Control Vacuum Solenoid and note operation.
With the DRBIIIt, actuate the Speed Control Vent Solenoid and note operation.
Choose the conclusion that best matches the solenoids operation?All
Vacuum Solenoid not operating
Go To 2
Vent Solenoid not operating
Go To 6
Both S/C Solenoids not operating
Go To 10
Both S/C Solenoids operating
Go To 15
2 Turn the ignition off.
Disconnect the Speed Control Servo harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the Speed Control Vacuum Solenoid.
Using a 12-volt test light connected to 12-volts, probe the Speed Control Vacuum
Solenoid Control circuit.
Does the test light illuminate brightly and flash?All
Ye s®Replace the Speed Control Servo.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No®Go To 3
3 Turn the ignition off.
Disconnect the S/C Servo harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Speed Control Vacuum Solenoid Control circuit
between the PCM harness connector and Speed Control Servo harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the Speed Control Vacuum Solenoid Control circuit for an
open.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
4 Turn the ignition off.
Disconnect the S/C Servo harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Speed Control Vacuum Solenoid Control circuit in the
PCM harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Speed Control Vacuum Solenoid Control circuit for a
short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No®Go To 5
249
SPEED CONTROL
P1595-SPEED CONTROL SOLENOID CIRCUITS ÐContinued

TEST ACTION APPLICABILITY
5 If the 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 - 4.
6 Turn the ignition off.
Disconnect the Speed Control Servo harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the Speed Control Vent Solenoid.
Using a 12-volt test light connected to 12-volts, probe the Speed Control Vent
Solenoid Control circuit in the Speed Control Servo harness connector.
Does the test light illuminate brightly and flash?All
Ye s®Replace the Speed Control Servo.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No®Go To 7
7 Turn the ignition off.
Disconnect the S/C Servo harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Speed Control Vent Solenoid Control circuit between
the PCM harness connector and Speed Control Servo harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair the Speed Control Vacuum Solenoid Control circuit for an
open.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
8 Turn the ignition off.
Disconnect the S/C Servo harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Speed Control Vent Solenoid Control circuit in the
PCM harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Speed Control Vacuum Solenoid Control circuit for a
short to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No®Go To 9
9 If the 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 - 4.
250
SPEED CONTROL
P1595-SPEED CONTROL SOLENOID CIRCUITS ÐContinued

TEST ACTION APPLICABILITY
10 Turn the ignition off.
Disconnect the S/C Servo harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the S/C Brake Switch Output
circuit in the S/C Servo harness connector.
Does the test light illuminate brightly?All
Ye s®Replace the Speed Control Servo.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No®Go To 11
11 Turn the ignition off.
Disconnect the Speed Control Servo harness connector.
Disconnect the Brake Lamp Switch harness connector.
Measure the resistance of the Speed Control Brake Switch Output circuit between
the Speed Control Servo harness connector and Brake Lamp Switch harness
connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 12
No®Repair the Speed Control Brake Switch Output circuit for an
open.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
12 Disconnect the Brake Lamp Switch harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Speed Control Power Supply
circuit in the Brake Lamp Switch harness connector.
Does the test light illuminate brightly?All
Ye s®Replace the Brake Lamp Switch.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
No®Go To 13
13 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the Brake Lamp Switch harness connector.
Measure the resistance of the Speed Control Power Supply circuit between the PCM
harness connector and the Brake Lamp Switch harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 14
No®Repair the Speed Control Supply circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
14 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 - 4.
251
SPEED CONTROL
P1595-SPEED CONTROL SOLENOID CIRCUITS ÐContinued

TEST ACTION APPLICABILITY
15 Turn the ignition off.
Disconnect the S/C Servo harness connector.
Using a 12-volt test light connected to 12-volts, probe the ground circuit in the S/C
Servo harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 16
No®Repair the ground circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 4.
16WARNING: 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 - 4.
No®Test Complete.
252
SPEED CONTROL
P1595-SPEED CONTROL SOLENOID CIRCUITS 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.
256
STARTING
*ENGINE CRANKS DOES NOT START ÐContinued