CHRYSLER VOYAGER 2001 Service Manual

ZONE CALIBRATION FAULT - MANUAL A/C
When Monitored: When the HVAC Door Recalibration is executed. With the ignition on
(door actuator(s)/circuit(s) shorted low only).
Set Condition: If the Blend Door (Driver [Zone]) drive span found is outside the tolerance.
If the Blend Door Actuator (Driver [Zone])/circuit is open. If the Blend Door(s) (Driver
[Zone], Pass, Rear), Mode Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s)
are shorted low. (This will also set Blend Calibration/Overcurrent (Front, Rear), Mode
Calibration/Overcurrent (Front, Rear), Recirculation Calibration/Overcurrent, Zone
Calibration/Overcurrent DTCs.)
POSSIBLE CAUSES
HVAC DTC(S) PRESENT
DOOR ACTUATOR
BLEND ACTUATOR/LINKAGE/DOOR
RECIRCULATION ACTUATOR/LINKAGE/DOOR
MODE ACTUATOR/LINKAGE/DOOR
DOOR ACTUATOR DRIVER CIRCUIT OPEN
COMMON DOOR DRIVER CIRCUIT OPEN
A/C - HEATER CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: All Overcurrent DTCs must be repaired before diagnosing Calibra-
tion messages.
Turn the ignition on.
With the DRBIIIt, read HVAC DTCs.
Does the DRBIIItdisplay any HVAC DTCs?All
Ye s®Return to the symptom list and choose the symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 2
522
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Remove the applicable door actuator (Blend [Driver (Zone), Passenger], Recircula-
tion, Mode) from the A/C - Heater Housing Assembly.
Disconnect the door actuator harness connector.
By hand, attempt to rotate the door actuator in both directions.
Did the door actuator turn in either direction?All
Ye s®Replace the door actuator in accordance with the Service Infor-
mation.
Perform BODY VERIFICATION TEST - VER 1.
No: Blend Actuator (Driver [Zone], Pass)
Go To 3
No: Recirculation Door Actuator
Go To 4
No: Mode Door Actuator
Go To 5
3 Turn the ignition off.
Remove the applicable blend door actuator (Driver [Zone], Passenger) from the A/C
- Heater Housing Assembly.
Disconnect the blend door actuator harness connector.
Set the applicable blend control switch knob (Driver [Zone], Passenger) to the full
cold position.
Connect a 12-volt Test Light across the blend door actuator harness connector.
Turn the ignition on.
While monitoring the test light, manually sweep the applicable blend control switch
knob (Driver [Zone], Passenger) very slowly from full cold to full hot.
While monitoring the test light, manually sweep the applicable blend control switch
knob (Driver [Zone], Passenger) very slowly from full hot to full cold.
Does the test light start to flash and stay flashing through the entire range?All
Ye s®Inspect A/C - Heater Housing for missing & broken actuator
linkage. Inspect linkage & actuator for broken & missing teeth.
Check doors for binding & loss of full range. Repair as necessary.
If Ok, replace the actuator in accordance with the Service Info.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 6
523
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
4 Turn the mode door knob to the Panel, Bi-level, or Floor position.
Turn the ignition off.
Remove the Recirculation Door Actuator from the A/C - Heater Housing Assembly.
Disconnect the Recirculation Door Actuator harness connector.
Connect a 12-volt Test Light across the Recirculation Door Actuator harness
connector.
Turn the ignition on.
If the LED on the recirculation mode switch is illuminated, manually press the
recirculation mode switch to turn the recirculation mode off.
While monitoring the test light, manually press the recirculation mode switch on
(LED on).
While monitoring the test light, manually press the recirculation mode switch off
(LED off).
Does the test light flash 4 times after pressing the switch on and 2 times after
pressing it off?All
Ye s®Inspect the linkage and the actuator for broken and missing
teeth. Check the door for binding and loss of full range. Repair as
necessary. If Ok, replace the door actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 6
5 Turn the ignition off.
Remove the Mode Door Actuator from the A/C - Heater Housing Assembly.
Disconnect the Mode Door Actuator harness connector.
Turn the mode select switch knob to the panel position, then to the defrost position,
then back to the panel position.
Connect a 12-volt Test Light across the Mode Door Actuator harness connector.
Turn the ignition on.
While monitoring the test light, turn the mode select switch knob to the first detent
after the panel position.
Repeat the previous step for each detent, until reaching the defrost mode position.
Does the test light flash four times after turning the mode select switch knob to each
detent?All
Ye s®Inspect A/C - Heater Housing for missing & broken actuator
linkage. Inspect linkage & actuator for broken & missing teeth.
Check doors for binding & loss of full range. Repair as necessary.
If Ok, replace the actuator in accordance with the Service Info.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 6
6 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Remove the applicable door actuator (Blend [Driver (Zone), Passenger], Recircula-
tion, Mode) from the A/C - Heater Housing Assembly.
Disconnect the door actuator harness connector.
Measure the resistance of the applicable door driver circuit (Blend [Driver (Zone),
Passenger], Recirculation, Mode) between the A/C - Heater Control Module C1
harness connector and the door actuator harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 7
No®Repair the applicable door driver circuit (Blend [Driver (Zone),
Passenger], Recirculation, Mode) for an open.
Perform BODY VERIFICATION TEST - VER 1.
524
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Remove the applicable door actuator (Blend [Driver (Zone), Passenger], Recircula-
tion, Mode) from the A/C - Heater Housing Assembly.
Disconnect the door actuator harness connector.
Measure the resistance of the Common Door Driver circuit between the applicable
door actuator harness connector (Blend [Driver (Zone), Passenger], Recirculation,
Mode) and the A/C - Heater Control Module C1 harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the Common Door Driver circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
525
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

Symptom List:
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
MODE OVERCURRENT (ACTIVE) - MANUAL A/C
REAR BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
REAR MODE OVERCURRENT (ACTIVE) - MANUAL A/C
RECIRC OVERCURRENT (ACTIVE) - MANUAL A/C
ZONE OVERCURRENT (ACTIVE) - MANUAL A/C
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be BLEND OVERCURRENT (AC-
TIVE) - MANUAL A/C.
When Monitored and Set Condition:
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
MODE OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
REAR BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
REAR MODE OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
RECIRC OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
526
HEATING & A/C

ZONE OVERCURRENT (ACTIVE) - MANUAL A/C
When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
POSSIBLE CAUSES
MODE DOOR ACTUATOR SHORTED
RECIRCULATION DOOR ACTUATOR SHORTED
PASSENGER BLEND DOOR ACTUATOR SHORTED
DRIVER BLEND DOOR ACTUATOR SHORTED
DOOR DRIVER CIRCUIT SHORTED TO GROUND
DOOR DRIVER CIRCUITS SHORTED TOGETHER
A/C - HEATER CONTROL MODULE
REAR BLEND DOOR ACTUATOR SHORTED
REAR MODE DOOR ACTUATOR SHORTED
REAR A/C HEATER UNIT WIRING HARNESS SHORTED
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Mode Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time.
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 2
No®Replace the Mode Door Actuator in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
527
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Disconnect the Recirculation Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 3
No®Replace the Recirculation Door Actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the Passenger Blend Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 4
No®Replace the Passenger Blend Door Actuator in accordance with
the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
528
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
4NOTE: If vehicle is equipped with a base HVAC system, answer yes to the
question.
Turn the ignition off.
Disconnect the Driver (zone) Blend Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 5
No®Replace the Driver Blend Door Actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
5NOTE: If vehicle is equipped with a base HVAC or dual zone system, answer
yes to the question.
Turn the ignition off.
Disconnect the Rear A/C Heater Unit harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time..
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot. Perform
this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 6
No®Go To 8
6 Turn the ignition off.
Disconnect each door actuator harness connector (front actuators only).
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear A/C Heater Unit harness connector (if equipped with rear A/C).
Measure the resistance between ground and each HVAC door driver circuit.
Is the resistance below 10K ohms for any of the measurements?All
Ye s®Repair all door driver circuits with a resistance below 10K ohms
for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 7
529
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect each door actuator harness connector (front actuators only).
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear A/C Heater Unit harness connector (if equipped with rear A/C).
Measure the resistance between the Common Door Driver circuit and each other door
driver circuit.
Measure the resistance between the Recirculation Door Driver circuit and each other
door driver circuit.
Measure the resistance between the Mode Door Driver circuit and each other door
driver circuit.
Measure the resistance between the Passenger Blend Air Door Driver circuit and
each other door driver circuit.
Measure the resistance between the Driver Blend Door Driver circuit and each other
door driver circuit (if equipped with dual or 3 zone).
Measure the resistance between the Rear Common Door Driver circuit and each
other door driver circuit (if equipped with rear A/C).
Measure the resistance between the Rear Blend Door Driver circuit and each other
door driver circuit (if equipped with rear A/C).
Measure the resistance between the Rear Mode Door Driver circuit and each other
door driver circuit (if equipped with rear A/C).
Is the resistance below 10K ohms for any of the measurements?All
Ye s®Repair the door driver circuits that measured below 10K ohms for
a short to each other.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
8 Turn the ignition off.
Reconnect the Rear A/C Heater Unit harness connector.
Disconnect the Rear Blend Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time.
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot. Perform
this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Go To 9
No®Replace the Rear Blend Door Actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
530
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
9 Turn the ignition off.
Reconnect the Rear A/C Heater Unit harness connector.
Disconnect the Rear Mode Door Actuator harness connector.
Turn the ignition on.
With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time.
Slowly turn the mode door knob through each of it's different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot. Perform
this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?All
Ye s®Repair the Rear A/C Heater Unit wiring harness for a short to
ground or shorted together door driver circuits between the Rear
A/C Heater Unit and the rear mode and blend doors.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the Rear Mode Door Actuator in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
531
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C ÐContinued