ignition CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
4 Turn the ignition off to the lock position.
Disconnect the Body Control Module harness connector.
Disconnect the Headlamp Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Measure the voltage of the Front Fog Lamp Indicator circuit in the Headlamp Switch
harness connector.
Is the voltage above 0.5 volt?All
Ye s®Repair the Front Fog Lamp Indicator circuit for a short to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 5
5 If there are no possible causes remaining, view repair. All
Repair
Replace the Headlamp Switch.
Perform BODY VERIFICATION TEST - VER 1.
6 Turn the ignition off to the lock position.
Disconnect the Body Control Module harness connector.
Disconnect the Headlamp Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Front Fog Lamp Indicator circuit from the Body
Control Module harness connector to the Headlamp Switch harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Front Fog Lamp Indicator circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 7
7 If there are no possible causes remaining, view repair. All
Repair
Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
8 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?All
Ye s®Repair as necessary.
Perform BODY VERIFICATION TEST - VER 1.
No®Test Complete.
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FRONT FOG LAMP INDICATOR OPEN ÐContinued

Symptom:
FRONT FOG LAMP INDICATOR SHORT TO GROUND
POSSIBLE CAUSES
INTERMITTENT WIRING AND CONNECTORS
FRONT FOG LAMP INDICATOR CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, record and erase Body Control Module DTC's.
Turn the ignition off, wait 15 seconds, then turn the ignition on.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay FRONT FOG LAMP INDICATOR SHORT TO GROUND?All
Ye s®Go To 2
No®Go To 6
2 Turn the ignition off to the lock position.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Turn ON the Front Fog Lamps.
Using a 12-volt test light connected to ground, back probe the Rear Fog Lamp
Indicator circuit in the Headlamp Switch harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Go To 4
3 If there are no possible causes remaining, view repair. All
Repair
Replace the Headlamp Switch.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off to the lock position.
Disconnect the Body Control Module harness connector.
Disconnect the Headlamp Switch harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the Front Fog Lamp Indicator circuit.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Front Fog Lamp Indicator circuit for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 5
5 If there are no possible causes remaining, view repair. All
Repair
Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
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Symptom:
FUEL LEVEL SENDING UNIT INPUT OPEN
When Monitored and Set Condition:
FUEL LEVEL SENDING UNIT INPUT OPEN
When Monitored: With the ignition on.
Set Condition: Fuel Level Input to the BCM is greater than 9.8 volts for greater than 62.5
milliseconds.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUEL LEVEL SENSOR SIGNAL SHORTED TO B+
GROUND CIRCUIT OPEN
FUEL LEVEL SENDING UNIT OPERATION
FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN
BCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase DTCs.
Cycle the ignition off and on, leaving ignition key on for at least 15 seconds.
With the DRBIIItin Body Computer, read DTCs.
Does the DTC reset?All
Ye s®Go To 2
No®Go To 7
2 Turn the ignition off.
Disconnect the Fuel Tank Module harness connector.
Turn the ignition on.
NOTE: The BCM sends out a low current 12 volt signal on the Fuel Level
Sensor Signal circuit. This low current should not illuminate a 12 volt test
light.
Using a 12-volt test light connected to ground, probe the Fuel Level Sensor Signal
circuit in the Fuel Tank Module harness connector.
Does the test light illuminate?All
Ye s®Repair the Fuel Level Sensor Signal circuit shorted to battery
voltage.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 3
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TEST ACTION APPLICABILITY
3 Turn the ignition on.
Disconnect the Fuel Tank Module harness connector.
Measure the resistance of the Ground circuits in the Fuel Tank Module harness
connector.
Is the resistance below 5.0 ohms for both measurements?All
Ye s®Go To 4
No®Repair the Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the Fuel Tank Module harness connector.
Turn the ignition on.
With the DRBIIItin Body Computer then Sensors, monitor the Fuel Sensor.
Using a jumper wire, jumper the Fuel Level Sensor Signal circuit to the ground
circuit in the Fuel Tank Module harness connector.
Does the DRB display below 0.5 volt?All
Ye s®Replace the Fuel Level Sending Unit.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 5
5 Turn the ignition off.
Disconnect the Fuel Tank Module harness connector.
Disconnect the BCM C3 harness connector.
Measure the resistance of the Fuel Level Sensor Signal circuit between the Fuel Tank
Module harness connector and the BCM harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the Fuel Level Sensor Signal for an open.
Perform BODY VERIFICATION TEST - VER 1.
6 If there are no possible causes remaining, view repair. All
Repair
Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
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.
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.
573
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FUEL LEVEL SENDING UNIT INPUT OPEN ÐContinued

Symptom:
FUEL LEVEL SENDING UNIT INPUT SHORT
When Monitored and Set Condition:
FUEL LEVEL SENDING UNIT INPUT SHORT
When Monitored: With the ignition on.
Set Condition: Fuel Level Input to the BCM is less than 2 volts for greater than 62.5
milliseconds.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUEL LEVEL SENDING UNIT OPERATION
FUEL LEVEL SENSOR SIGNAL SHORTED TO GROUND
BCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase DTCs.
Cycle the ignition off and on, leaving ignition key on for at least 15 seconds.
With the DRBIIItin Body Computer, read DTCs.
Does the DTC reset?All
Ye s®Go To 2
No®Go To 5
2 Turn the ignition on.
With the DRBIIItin Body Computer and then Sensors, monitor the Fuel Sensor.
Disconnect the Fuel Tank Module harness connector.
Does the Fuel Sensor voltage go above 9.5 volts?All
Ye s®Replace the Fuel Level Sending Unit.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 3
3 Turn the ignition off.
Disconnect the BCM C3 harness connector.
Disconnect Fuel Tank Module harness connector.
Measure the resistance of the Fuel Level Sensor Signal circuit in the BCM harness
connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Fuel Level Sensor Signal circuit for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 4
574
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Symptom:
IOD WAKEUP CLUSTER OUTPUT OPEN
When Monitored and Set Condition:
IOD WAKEUP CLUSTER OUTPUT OPEN
When Monitored: With the ignition on.
Set Condition: The BCM is active and the Instrument Cluster does not responed on the
Instrument Cluster Wake Up Sense circuit.
POSSIBLE CAUSES
INTERMITTENT CONDITION
INSTRUMENT CLUSTER WAKE UP SENSE CKT OPEN
INSTRUMENT CLUSTER WAKE UP SENSE CKT SHORT TO GROUND
INSTRUMENT CLUSTER
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase DTCs.
Cycle the ignition off and on several times, leaving ignition key on for at least 15
seconds.
With the DRBIIItin Body Computer, read DTCs.
Does the DTC reset?All
Ye s®Go To 2
No®Go To 5
2 Turn the ignition off.
Disconnect the BCM C4 harness connector.
Turn the ignition on.
Measure the voltage of the Instrument Cluster Wake Up Sense circuit in the BCM C4
harness connector.
Is the voltage above 10.0 volts?All
Ye s®Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 3
576
INSTRUMENT CLUSTER

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the Instrument Cluster harness connector.
Disconnect the BCM C4 harness connector.
Measure the resistance of the Instrument Cluster Wake Up Sense circuit between the
BCM C4 harness connector and the MIC harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the Instrument Cluster Wake Up Sense circuit for an
open.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the Instrument Cluster harness connector.
Disconnect the BCM C4 harness connector.
Measure the resistance of the Instrument Cluster Wake Up Sense circuit in the MIC
harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Instrument Cluster Wake Up Sense circuit for a
shorted to ground.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the Instrument Cluster.
Perform BODY VERIFICATION TEST - VER 1.
5WARNING: 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.
577
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IOD WAKEUP CLUSTER OUTPUT OPEN ÐContinued

Symptom:
IOD WAKEUP CLUSTER OUTPUT SHORT
When Monitored and Set Condition:
IOD WAKEUP CLUSTER OUTPUT SHORT
When Monitored: With the ignition on.
Set Condition: The BCM is active and senses the Instrument Cluster Wake Up Sense
circuit shorted high.
POSSIBLE CAUSES
INTERMITTENT CONDITION
INSTRUMENT CLUSTER WAKE UP SENSE CKT SHORTED TO VOLTAGE
INSTRUMENT CLUSTER
BODY CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase DTCs.
Cycle the ignition off and on several times, leaving the ignition key on for at least 15
seconds.
With the DRBIIItin Body Computer, read DTCs.
Does the DTC reset?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition off.
Disconnect the BCM C4 harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Instrument Cluster Wake
Up Sense circuit.
Is the test light illuminated?All
Ye s®Go To 3
No®Replace the Body Control Module.
Perform BODY VERIFICATION TEST - VER 1.
578
INSTRUMENT CLUSTER

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the BCM C4 harness connector.
Disconnect the Instrument Cluster harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Instrument Cluster Wake
Up Sense circuit.
Is the test light illuminated?All
Ye s®Repair the Instrument Cluster Wake Up Sense circuit for a short
to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the Instrument Cluster.
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.
579
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IOD WAKEUP CLUSTER OUTPUT SHORT ÐContinued

Symptom:
LEFT TURN SIGNAL INDICATOR OPEN (HIGHLINE)
When Monitored and Set Condition:
LEFT TURN SIGNAL INDICATOR OPEN (HIGHLINE)
When Monitored: With the ignition on.
Set Condition: The BCM detects an open in the Left Turn Indicator Driver.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUSED B+ CIRCUIT
MESSAGE CENTER OPERATION
LEFT TURN INDICATOR DRIVER SHORTED TO GROUND
LEFT TURN INDICATOR DRIVER OPEN
BCM
TEST ACTION APPLICABILITY
1 Turn the ignition on.
Monitor the Left Turn Signal Indicator.
Operate the Left Turn Signal.
Is the Indicator lamp operating correctly?All
Ye s®Go To 2
No®Go To 3
2WARNING: 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.
580
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