body CHRYSLER VOYAGER 2001 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2001, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2001Pages: 4284, PDF Size: 83.53 MB
Page 4 of 4284
TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1SYSTEM COVERAGE...............................................1
1.2SIX-STEP TROUBLESHOOTING PROCEDURE..........................1
2.0 IDENTIFICATION OF SYSTEM.............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION......................1
3.1AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM........2
3.1.1DRIVER AIRBAG...........................................3
3.1.2CLOCKSPRING............................................4
3.1.3PASSENGER AIRBAG......................................4
3.1.4SEAT BELT TENSIONER (SBT)...............................5
3.1.5SEAT BELT SWITCHES (SBS)................................5
3.1.6SIDE IMPACT AIRBAG CONTROL MODULE (SIACM)............5
3.1.7SEAT AIRBAGS (SAB)......................................6
3.1.8ORC/SIACM DIAGNOSTIC TROUBLE CODES..................6
3.1.9ACTIVE CODES...........................................7
3.1.10STORED CODES..........................................7
3.2AUDIO SYSTEM....................................................7
3.2.1REMOTE RADIO CONTROLS................................8
3.2.2CD CHANGER.............................................8
3.3BODY CONTROL MODULE...........................................8
3.4CHIME WARNING SYSTEM...........................................9
3.4.1CHIME PRIORITY..........................................9
3.4.2CHIME ON CONDITIONS....................................9
3.4.3WARNING LAMP ANNOUNCEMENT.........................10
3.4.4OTHER CHIME ON CONDITIONS............................10
3.5COMMUNICATION.................................................11
3.6DOOR AJAR SYSTEM..............................................12
3.7EXTERIOR LIGHTING SYSTEM......................................12
3.7.1HEADLAMP POWER......................................12
3.7.2HEADLAMP SWITCH......................................12
3.7.3PARK LAMP RELAY.......................................12
3.7.4FOG LAMP RELAY........................................12
3.7.5FOG LAMPS.............................................12
3.7.6EXTERIOR LIGHTING BATTERY SAVER......................13
3.7.7AUTO HEADLAMPS.......................................13
3.8FRONT CONTROL MODULE.........................................13
3.8.1CONTROLLED POWER FEEDS.............................13
3.8.2RELAY CONTROLS.......................................14
3.8.3ELECTRICAL INPUTS.....................................15
3.9HEATING & A/C...................................................16
3.9.1AUTOMATIC TEMPERATURE CONTROL (ATC)................16
3.9.1.1CABIN HEATER..........................................16
3.9.1.2SYSTEM OPERATION.....................................16
3.9.1.3BLOWER MOTOR OPERATION.............................16
3.9.1.4INFRARED SENSORS.....................................16
3.9.1.5REAR ATC SWITCH.......................................16
3.9.1.6COOLDOWN TESTING....................................16
3.9.1.7ACTIVE AND STORED TROUBLE CODES....................17
3.9.2MANUAL TEMPERATURE CONTROL.........................17
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TABLE OF CONTENTS - Continued
ORC, CALIBRATION MISMATCH - STORED.................................75
ORC, CLUSTER MESSAGE MISMATCH - STORED...........................75
ORC, DRIVER SBS OPEN - STORED......................................75
ORC, DRIVER SBS SHORT TO BATTERY - STORED.........................75
ORC, DRIVER SBS SHORT TO GROUND - STORED.........................75
ORC, DRIVER SBT CIRCUIT OPEN - STORED..............................75
ORC, DRIVER SBT CIRCUIT SHORT - STORED.............................75
ORC, DRIVER SBT SHORT TO BATTERY - STORED.........................75
ORC, DRIVER SBT SHORT TO GROUND - STORED.........................75
ORC, DRIVER SQUIB 1 CIRCUIT OPEN - STORED...........................75
ORC, DRIVER SQUIB 1 CIRCUIT SHORT - STORED.........................75
ORC, DRIVER SQUIB 1 SHORT TO BATTERY - STORED......................75
ORC, DRIVER SQUIB 1 SHORT TO GROUND - STORED......................75
ORC, DRIVER SQUIB 2 CIRCUIT OPEN - STORED...........................75
ORC, DRIVER SQUIB 2 CIRCUIT SHORT - STORED.........................75
ORC, DRIVER SQUIB 2 SHORT TO BATTERY - STORED......................75
ORC, DRIVER SQUIB 2 SHORT TO GROUND - STORED......................75
ORC, LOSS OF IGNITION RUN ONLY - STORED.............................75
ORC, LOSS OF IGNITION RUN-START - STORED............................75
ORC, NO CLUSTER MESSAGE - STORED..................................75
ORC, NO ODOMETER MESSAGE - STORED................................75
ORC, PASSENGER SBS OPEN - STORED..................................75
ORC, PASSENGER SBS SHORT TO BATTERY - STORED.....................75
ORC, PASSENGER SBS SHORT TO GROUND - STORED.....................75
ORC, PASSENGER SBT CIRCUIT OPEN - STORED..........................75
ORC, PASSENGER SBT CIRCUIT SHORT - STORED.........................75
ORC, PASSENGER SBT SHORT TO BATTERY - STORED.....................75
ORC, PASSENGER SBT SHORT TO GROUND - STORED.....................75
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN - STORED......................75
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT - STORED.....................75
ORC, PASSENGER SQUIB 1 SHORT TO BATTERY - STORED.................75
ORC, PASSENGER SQUIB 1 SHORT TO GROUND - STORED.................75
ORC, PASSENGER SQUIB 2 CIRCUIT OPEN - STORED......................75
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT - STORED.....................75
ORC, PASSENGER SQUIB 2 SHORT TO BATTERY - STORED.................75
ORC, PASSENGER SQUIB 2 SHORT TO GROUND - STORED.................75
ORC, VEHICLE BODY STYLE UNKNOWN - STORED.........................75
ORC, WARNING INDICATOR CIRCUIT OPEN - STORED......................75
ORC, WARNING INDICATOR CIRCUIT SHORT - STORED.....................75
ORC, CLUSTER MESSAGE MISMATCH - ACTIVE............................82
ORC, DRIVER SBS OPEN - ACTIVE.......................................84
ORC, DRIVER SBS SHORT TO BATTERY - ACTIVE..........................86
ORC, DRIVER SBS SHORT TO GROUND - ACTIVE..........................88
ORC, DRIVER SBT CIRCUIT OPEN - ACTIVE................................90
ORC, DRIVER SBT CIRCUIT SHORT - ACTIVE..............................92
ORC, DRIVER SBT SHORT TO BATTERY - ACTIVE..........................94
ORC, DRIVER SBT SHORT TO GROUND - ACTIVE...........................96
ORC, DRIVER SQUIB 1 CIRCUIT OPEN - ACTIVE............................98
ORC, DRIVER SQUIB 1 CIRCUIT SHORT - ACTIVE..........................101
ORC, DRIVER SQUIB 1 SHORT TO BATTERY - ACTIVE......................104
ORC, DRIVER SQUIB 1 SHORT TO GROUND - ACTIVE......................107
ORC, DRIVER SQUIB 2 CIRCUIT OPEN - ACTIVE...........................110
ORC, DRIVER SQUIB 2 CIRCUIT SHORT - ACTIVE..........................113
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TABLE OF CONTENTS - Continued
ORC, DRIVER SQUIB 2 SHORT TO BATTERY - ACTIVE......................116
ORC, DRIVER SQUIB 2 SHORT TO GROUND - ACTIVE......................119
ORC, INTERROGATE LEFT SIACM - ACTIVE...............................122
ORC, INTERROGATE RIGHT SIACM - ACTIVE..............................123
ORC, INTERROGATE RIGHT SIACM - STORED.............................124
ORC, NO RIGHT SIACM MESSAGE - STORED.............................124
RIGHT SIACM, NO PCI TRANSMISSION - STORED.........................124
RIGHT SIACM, NO PCM MESSAGE - STORED.............................124
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - STORED......................124
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - STORED....................124
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - STORED................124
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - STORED.................124
ORC, NO CLUSTER MESSAGE - ACTIVE..................................126
ORC, NO LEFT SIACM MESSAGE - ACTIVE...............................128
ORC, NO ODOMETER MESSAGE - ACTIVE................................129
ORC, NO PCI TRANSMISSION - STORED.................................130
ORC, NO RIGHT SIACM MESSAGE - ACTIVE..............................131
ORC, NOT CONFIGURED FOR SAB - ACTIVE..............................132
ORC, NOT CONFIGURED FOR SAB - STORED.............................134
ORC, PASSENGER SBS OPEN - ACTIVE..................................135
ORC, PASSENGER SBS SHORT TO BATTERY - ACTIVE.....................137
ORC, PASSENGER SBS SHORT TO GROUND - ACTIVE.....................139
ORC, PASSENGER SBT CIRCUIT OPEN - ACTIVE..........................141
ORC, PASSENGER SBT CIRCUIT SHORT - ACTIVE.........................143
ORC, PASSENGER SBT SHORT TO BATTERY - ACTIVE.....................145
ORC, PASSENGER SBT SHORT TO GROUND - ACTIVE.....................147
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN - ACTIVE......................149
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT - ACTIVE.....................152
ORC, PASSENGER SQUIB 1 SHORT TO BATTERY - ACTIVE.................154
ORC, PASSENGER SQUIB 1 SHORT TO GROUND - ACTIVE.................157
ORC, PASSENGER SQUIB 2 CIRCUIT OPEN - ACTIVE......................159
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT - ACTIVE.....................162
ORC, PASSENGER SQUIB 2 SHORT TO BATTERY - ACTIVE.................164
ORC, PASSENGER SQUIB 2 SHORT TO GROUND - ACTIVE.................167
ORC, VEHICLE BODY STYLE UNKNOWN - ACTIVE.........................169
ORC, WARNING INDICATOR CIRCUIT OPEN - ACTIVE......................171
ORC, WARNING INDICATOR CIRCUIT SHORT - ACTIVE.....................171
RIGHT SIACM ACCELEROMETER 1 - ACTIVE..............................173
RIGHT SIACM ACCELEROMETER1-STORED.............................173
RIGHT SIACM ACCELEROMETER 2 - ACTIVE..............................173
RIGHT SIACM ACCELEROMETER2-STORED.............................173
RIGHT SIACM INTERNAL 1 - ACTIVE.....................................173
RIGHT SIACM INTERNAL 1 - STORED....................................173
RIGHT SIACM OUTPUT DRIVER 1 - ACTIVE...............................173
RIGHT SIACM OUTPUT DRIVER1-STORED..............................173
RIGHT SIACM, LOSS OF IGNITION RUN-START - ACTIVE....................173
RIGHT SIACM, NO PCI TRANSMISSION - ACTIVE..........................173
RIGHT SIACM, NO PCM MESSAGE - ACTIVE..............................176
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE.......................177
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE.....................180
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE..................182
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE..................185
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES...............188
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TABLE OF CONTENTS - Continued
B1823 WATER PUMP CIRCUIT: OPEN.....................................323
B1823 WATER PUMP CIRCUIT: SHORT TO GROUND........................323
B1824 FAN SWITCH LINE SHORT TO GROUND............................324
CABIN HEATER CONTROL CIRCUIT OPEN (ACTIVE)........................325
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE)...........329
*CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE...............332
CHIME
*CHIME INOPERATIVE..................................................334
*KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING
PROPERLY...........................................................336
*PROBLEM WITH THE HIGH VEHICLE SPEED WARNING CHIME.............337
COMMUNICATION
ATC MESSAGES NOT RECEIVED........................................338
AUDIO MESSAGES NOT RECEIVED......................................339
BCM, PCI BUS SHORTED TO BATTERY...................................340
BCM, PCI BUS SHORTED TO GROUND...................................340
FCM, PCI BUS SHORTED TO BATTERY...................................340
FCM, PCI BUS SHORTED TO GROUND...................................340
COUNTRY CODE NOT PROGRAMMED...................................342
FCM MESSAGES NOT RECEIVED........................................343
FCM, BCM COMMUNICATION FAULT.....................................344
FCM, HVAC COMMUNICATION FAULT....................................345
FCM, PCI INTERNAL FAULT.............................................346
FCM, PCM COMMUNICATION FAULT.....................................347
FCM, RADIO COMMUNICATION FAULT...................................348
FCM, TCM COMMUNICATION FAULT.....................................349
IGNITION MUX SWITCH INPUT OPEN....................................350
IGNITION MUX SWITCH INPUT SHORT...................................352
IGNITION RUN OUTPUT SHORT.........................................353
INTERNAL BCM FAILURE...............................................357
LEFT PSD MESSAGES NOT RECEIVED...................................358
LIFTGATE MODULE MESSAGES NOT RECEIVED...........................359
MIC MESSAGES NOT RECEIVED........................................360
MSM MESSAGES NOT RECEIVED.......................................361
NO PCI MESSAGES FROM CD CHANGER.................................362
ORC MESSAGES NOT RECEIVED........................................364
OTIS MESSAGES NOT RECEIVED.......................................365
PCI INTERNAL HARDWARE FAILURE.....................................366
PCM MESSAGES NOT RECEIVED........................................367
RADIO MEM MSG NOT RECEIVED.......................................368
RIGHT PSD MESSAGES NOT RECEIVED..................................369
RUN/START HARDWIRE INPUT FAILURE..................................370
SKIM MESSAGES NOT RECEIVED.......................................371
TCM MESSAGES NOT RECEIVED........................................372
*BUS +/- SIGNALS OPEN FROM AUTOMATIC TEMPERATURE CONTROL
MODULE.............................................................373
*BUS +/- SIGNALS OPEN FROM MEMORY SEAT/MIRROR MODULE...........375
*BUS +/- SIGNALS OPEN FROM SENTRY KEY IMMOBILIZER MODULE........377
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM BODY CONTROL
MODULE.............................................................379
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM HVAC..................381
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TABLE OF CONTENTS - Continued
INTERNAL EEPROM WRITE ERROR......................................927
INTERNAL TRANSMIT FAILURE..........................................928
INTERNAL ULTRASONIC FAULT.........................................929
LOOPBACK ERROR....................................................935
NO VALID MESSAGES RECEIVED........................................936
PCI BUS SHORTED TO BATTERY........................................937
PCI BUS SHORTED TO GROUND........................................938
PCM MESSAGES NOT RECEIVED........................................939
VEHICLE THEFT ALARM INDICATOR OUTPUT OPEN.......................940
VEHICLE THEFT ALARM INDICATOR OUTPUT SHORT......................941
*ALARM TRIPS ON ITS OWN............................................942
*HOOD DOES NOT TRIP VTSS..........................................943
*LEFT FRONT DOOR DOES NOT TRIP VTSS..............................944
*LEFT SLIDING DOOR DOES NOT TRIP VTSS.............................945
*LIFTGATE DOES NOT TRIP VTSS.......................................946
*REPEATER LAMPS INOPERATIVE WITH ALARM...........................947
*RIGHT FRONT DOOR DOES NOT TRIP VTSS.............................948
*RIGHT SLIDING DOOR DOES NOT TRIP VTSS............................949
*VTSS INDICATOR INOPERATIVE........................................950
*VTSS INDICATOR LAMP INOPERATIVE...................................951
*VTSS SIREN INOP....................................................952
*VTSS WILL NOT ARM..................................................955
WINDSHIELD WIPER & WASHER
FR WIPER HI-LO RELAY OPEN..........................................956
FR WIPER HI-LO RELAY SHORT TO BATT.................................958
FRONT WASH SWITCH INPUT STUCK....................................959
FRONT WASHER OUTPUT OPEN........................................961
FRONT WIPER NOT PARKED............................................963
FRONT WIPER ON RELAY OPEN........................................965
FRONT WIPER ON RELAY SHORT TO BATT...............................966
FRONT WIPER PARK SWITCH SHORT TO GND............................967
FRONT WIPER SWITCH MUX INPUT OPEN................................969
FRONT WIPER SWITCH MUX INPUT SHORT TO GROUND...................971
HEADLAMP WASHER RELAY OPEN......................................973
HEADLAMP WASHER RELAY SHORT TO BATT.............................975
REAR WASH SWITCH INPUT STUCK.....................................976
REAR WASHER OUTPUT OPEN.........................................978
REAR WIPER OUTPUT OPEN...........................................980
REAR WIPER OUTPUT SHORT TO GROUND..............................982
REAR WIPER SWITCH MUX INPUT OPEN.................................984
REAR WIPER SWITCH MUX INPUT SHORT TO GROUND....................986
VERIFICATION TESTS
VERIFICATION TESTS..................................................988
8.0 COMPONENT LOCATIONS..............................................995
8.1AIRBAG SYSTEM.................................................995
8.2BODY CONTROL MODULE.........................................996
8.3ENGINE CONTROL MODULE.......................................996
8.4HEATING & A/C...................................................996
8.4.1ACTUATORS ± FRONT LHD...............................996
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TABLE OF CONTENTS - Continued
8.4.2ACTUATOR ± FRONT RHD................................997
8.4.3ACTUATOR ± FRONT LHD................................997
8.4.4ACTUATOR ± FRONT RHD................................998
8.4.5EVAPORATOR TEMPERATURE SENSOR LHD................998
8.4.6EVAPORATOR TEMPERATURE SENSOR RHD...............999
8.4.7C202 CONNECTOR......................................999
8.4.8ACTUATORS ± REAR...................................1000
8.4.9REAR A/C HEATER UNIT CONNECTOR....................1000
8.5CABIN HEATER.................................................1001
8.5.1DIESEL CABIN HEATER ASSIST (CABIN HEATER) ASSEMBLY .1001
8.5.2C331 CONNECTOR.....................................1001
8.5.3C330 CONNECTOR.....................................1002
8.7MEMORY SYSTEM...............................................1002
8.7.1MEMORY SEAT MIRROR MEDULE/SEAT MOTORS..........1002
8.7.2MEMORY SEAT MIRROR MODULE CIRCUIT BREAKER.......1003
8.8OVERHEAD SWITCHES..........................................1003
8.9POWER FOLDING MIRRORS......................................1003
8.10POWER LIFTGATE SYSTEM.......................................1004
8.10.1MODULE..............................................1004
8.10.2PINCH SENSORS (TAPE SWITCH)........................1004
8.10.3LATCH ASSEMBLY......................................1005
8.11POWER DOOR LOCK/RKE SYSTEM................................1005
8.11.1DOOR LOCK MOTOR/AJAR SWITCH......................1005
8.11.1CYLINDER LOCK SWITCH...............................1005
8.11.3REMOTE KEYLESS ENTRY MODULE......................1006
8.12POWER SLIDING DOOR..........................................1006
8.12.1MODULE..............................................1006
8.12.2LOWER DRIVE UNIT....................................1006
8.12.3LATCH ASSEMBLY......................................1007
8.13VEHICLE THEFT SECURITY SYSTEM...............................1007
8.13.1RKE/THATCHAM ALARM MODULE........................1007
8.13.2RKE/THATCHAM ALARM MODULE CONNECTORS...........1007
8.13.3VTSS LED.............................................1008
8.13.4VTSS SIREN...........................................1008
8.13.5FRONT INTRUSION SENSOR.............................1009
8.13.6REAR INTRUSION SENSOR.............................1009
9.0 CONNECTOR PINOUTS...............................................1011
A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAY...................1011
A/C-HEATER CONTROL C2 (MTC) - BLACK/BLUE 10 WAY..................1011
AMBIENT TEMP SENSOR (EXCEPT BASE) - BLACK 2 WAY.................1011
ATC REMOTE SENSOR (ATC)-4WAY...................................1012
AUTO TEMP CONTROL C1 - WHITE 13 WAY..............................1012
AUTO TEMP CONTROL C2 - BLACK 13 WAY..............................1012
AUTO TEMP CONTROL C3-4WAY.....................................1012
BLOWER MOTOR RESISTOR C1 (MTC) - BLACK 6 WAY....................1013
BLOWER MOTOR RESISTOR C2 (MTC) - BLACK 2 WAY....................1013
BODY CONTROL MODULE C1 - BLACK/BLACK 6 WAY.....................1013
BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAY....................1014
BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY....................1015
BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY.....................1016
BODY CONTROL MODULE C5 - BLACK/BLACK 34 WAY....................1017
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Page 23 of 4284
TABLE OF CONTENTS - Continued
C200 - GRAY (BODY SIDE).............................................1018
C200 - GRAY (INSTRUMENT PANEL SIDE)................................1020
C201 - YELLOW (BODY SIDE)..........................................1021
C201 - YELLOW (INSTRUMENT PANEL SIDE).............................1022
C202 - GRAY (COMPONENT SIDE)......................................1022
C202 - GRAY (INSTRUMENT PANEL SIDE)................................1023
C304 - YELLOW (BODY SIDE)..........................................1023
C304 - YELLOW (SEAT SIDE)...........................................1023
C305 - GRAY (BODY SIDE).............................................1024
C306 - YELLOW (BODY SIDE)..........................................1024
C306 - YELLOW (SEAT SIDE)...........................................1024
C307 - GRAY (BODY SIDE).............................................1024
C307 - GRAY (SEAT SIDE).............................................1025
C311 - GRAY (BODY SIDE).............................................1025
C311 - GRAY (REAR A/C JUMPER SIDE).................................1026
C314 (HIGH LINE) - BLACK (BODY SIDE).................................1026
C314 (HIGH LINE) - BLACK (LIFTGATE SIDE).............................1027
C315 (HIGH LINE) - BLACK (BODY SIDE).................................1027
C315 (HIGH LINE) - BLACK (LIFTGATE SIDE).............................1027
C316 (POWER SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY
SIDE)...............................................................1028
C316 (POWER SLIDING DOOR) - BLACK (LEFT SLIDING DOOR SIDE)........1028
C317 (POWER SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY
SIDE)...............................................................1028
C317 (POWER SLIDING DOOR) - BLACK (RIGHT SLIDING DOOR SIDE)......1028
C322 (MEMORY) - BLACK (BODY SIDE)..................................1029
C322 (MEMORY) - BLACK (POWER SEAT SIDE)...........................1029
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY
SIDE................................................................1029
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT MANUAL SLIDING DOOR
SIDE)...............................................................1030
C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY
SID.................................................................1030
C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT MANUAL SLIDING DOOR
SIDE)...............................................................1030
C326 - YELLOW (SAFETY SEAT SIDE)...................................1030
C326 - YELLOW (SEAT SIDE)...........................................1030
C327 - YELLOW (SAFETY SEAT SIDE)...................................1031
C327 - YELLOW (SEAT SIDE)...........................................1031
C330 (DIESEL) - GRAY (CABIN HEATER JUMPER SIDE)....................1031
C330 (DIESEL) - LT. GRAY (BODY SIDE)..................................1031
C331 (DIESEL) - BLACK (CABIN HEATER JUMPER SIDE)...................1031
C331 (DIESEL) - GRAY (CABIN HEATED COMPONENT SIDE)................1032
CABIN HEATER ASSIST C1 (DIESEL) - BLACK 6 WAY......................1032
CABIN HEATER ASSIST C2 (DIESEL) - BLACK 2 WAY......................1032
CD CHANGER-8WAY................................................1033
CENTER DOME LAMP (BASE/HIGH LINE) - GRAY 3 WAY...................1033
CLOCKSPRING C1 - WHITE 6 WAY......................................1033
CLOCKSPRING C2 - YELLOW 4 WAY....................................1034
CLOCKSPRING C4 - BLACK 2 WAY......................................1034
CLOCKSPRING C5 - YELLOW 4 WAY....................................1034
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY........................1035
DATA LINK CONNECTOR - BLACK 16 WAY...............................1035
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TABLE OF CONTENTS - Continued
RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK
8 WAY ..............................................................1082
RIGHT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) -
BLACK/RED 20 WAY..................................................1082
RIGHT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) -
BLACK 6 WAY........................................................1082
RIGHT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4
WAY................................................................1083
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) -
BLACK 4 WAY........................................................1083
RIGHT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY. . . .1083
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY.....................1083
SIREN (UNITED KINGDOM) - BLACK 4 WAY..............................1083
THATCHAM ALARM MODULE C1 (UNITED KINGDOM) - BLACK 16 WAY.......1084
THATCHAM ALARM MODULE C2 (UNITED KINGDOM) - WHITE 4 WAY........1084
TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY..............1085
TXV SOLENOID (ATC)-2WAY.........................................1086
10.0 SCHEMATIC DIAGRAMS...............................................1087
10.1AIRBAG SYSTEM................................................1087
10.2AUDIO SYSTEM.................................................1088
10.2.1PREMIUM.............................................1088
10.2.2BASE.................................................1089
10.2.3CD CHANGER.........................................1090
10.2.4REMOTE RADIO CONTROLS.............................1091
10.3CABIN HEATER.................................................1092
10.4AUTOMATIC TEMPERATURE CONTROL SYSTEM....................1093
10.4.1FRONT ATC............................................1093
10.4.2REAR ATC.............................................1094
10.5COMMUNICATION...............................................1095
10.5.1PCM COMMUNICATION.................................1096
10.5.2ECM & CABIN HEATER ASSIST COMMUNICATION - DIESEL
ONLY.................................................1096
10.6DOOR AJAR WITH POWER SLIDING DOORS........................1097
10.7DOOR AJAR WITHOUT POWER SLIDING DOORS....................1098
10.8EXTERIOR LIGHTING............................................1099
10.9IGNITION SWITCH...............................................1100
10.10INSTRUMENT CLUSTER Ð BASE..................................1101
10.11INSTRUMENT CLUSTER & MESSAGE CENTER......................1102
10.12INTELLIGENT POWER MODULE/BODY CONTROL MODULE POWER AND
GROUNDS......................................................1103
10.13INTERIOR LIGHTING.............................................1104
10.14MANUAL TEMPERATURE CONTROLS..............................1105
10.14.1BASE MANUAL TEMPERATURE CONTROL SYSTEM LHD.....1105
10.14.2BASE MANUAL TEMPERATURE CONTROL SYSTEM RHD....1106
10.14.3DUAL-ZONE MANUAL TEMPERATURE CONTROL SYSTEM
LHD ..................................................1107
10.14.4DUAL-ZONE MANUAL TEMPERATURE CONTROL SYSTEM
RHD..................................................1108
10.14.5BLOWER MOTOR.......................................1109
10.15MEMORY SYSTEM...............................................1110
10.16OVERHEAD CONSOLE...........................................1111
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1.0 INTRODUCTION
The procedures contained in this manual include
all the specifications, instructions and graphics
needed to diagnose 2001 body system problems. The
diagnostics in this manual are based on the failure
condition or symptom being present at the time of
diagnosis.
Please follow the recommendations below when
choosing your diagnostic path.
1. First make sure the DRBIIItis communicating
with the appropriate modules; i.e., if the
DRBIIItdisplays a ªNo Responseº or a ªBus6
Signals Openº condition, you must diagnose that
first.
2. Read DTC's (diagnostic trouble codes) with the
DRBIIIt.
3. If no DTC's are present, identify the customer
complaint.
4. Once the DTC or customer complaint is identi-
fied, locate the matching test in the Table of
Contents and begin to diagnose the symptom.
All component location views are in Section 8.0. All
connector pinouts are in Section 9.0. All schematics
are in Section 10.0. All Charts and Graphs are in
Section 11.0.
An * placed before the symptom description indi-
cated a customer complaint.
When repairs are required, refer to the appropri-
ate service information for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added: carryover systems
may be enhanced. READ THIS MANUAL BEFORE
TRYING TO DIAGNOSE A VEHICLE DIAGNOS-
TIC TROUBLE CODE. It is recommended that you
review the entire manual to become familiar with all
the new and changed diagnostic procedures.
This book reflects many suggested changes from
readers of past issues. After using this book, if you
have any comments or suggestions, please fill out
the form in the back of this book and mail it back to
us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers all
2001 Chrysler Voyager and Caravan vehicles. This
diagnostic procedures manual also covers both left
hand drive (LHD) and right hand drive (RHD)
vehicles. There may be some slight differences in
the location views of components. If the location
views shown are on a LHD vehicle, a RHD vehicle
will be symmetrically opposite.
1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the body system is done in six basic
steps:
²verification of complaint
²verification of any related symptoms
²symptom analysis
²problem isolation
²repair of isolated problem
²verification of proper operation
2.0 IDENTIFICATION OF
SYSTEM
The vehicle systems that are part of the ªbodyº
system are:
²Airbag
²Audio
²Cabin Heater
²Chime
²Communication
²Door Ajar System
²Electrically heated system
²Exterior lighting
²Heating and A/C
²Instrument Cluster
²Interior Lighting
²Manual Temperature Control
²Memory Seat
²Overhead Console
²Power Door Lock/RKE
²Power Folding Mirrors
²Power Sliding Doors
²Power Liftgate
²Power windows
²Vehicle Theft Security System (VTSS)
²Windshield Wiper and Washer
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
The body system on the 2001 RG consists of a
combination of modules that communicate over the
PCI bus (Programmable Communication Interface
multiplex system). Through the PCI bus, informa-
tion about the operation of vehicle components and
circuits is relayed quickly to the appropriate mod-
ule(s). All modules receive all the information trans-
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GENERAL INFORMATION
Page 31 of 4284
mitted on the bus even though a module may not
require all information to perform its function. It
will only respond to messages ªaddressedº to it
through binary coding process. This method of data
transmission significantly reduces the complexity
of the wiring in the vehicle and the size of wiring
harnesses. All of the information about the func-
tioning of all the systems is organized, controlled,
and communicated by the PCI bus, which is de-
scribed in the Communication Section of this gen-
eral information.
3.1 AIRBAG SYSTEM/OCCUPANT
RESTRAINT CONTROLLER SYSTEM
The 2001 Minivan Airbag System contain the
following components: Occupant Restraint Control-
ler (ORC), Airbag Warning Indicator, Clockspring,
Driver and Passenger Airbags, Seat belt Tensioners
(SBT), Hall-effect Seat Belt Switches (SBS), Left
and Right Side Airbag Control Module (SIACM),
and Seat (mounted side) Airbags.
The Occupant Restraint Controller (ORC) is a
new type of Airbag Control Module (ACM) that
supports staged airbag deployment. Staged deploy-
ment is the ability to trigger airbag system squib
inflators all at once or individually as needed to
provide the appropriate restraint for the severity of
the impact. The ORC has four major functions: PCI
Bus communications, onboard diagnostics, impact
sensing, and component deployment. The ORC also
contains an energy-storage capacitor. This capaci-
tor stores enough electrical energy to deploy the
front airbag components for two seconds following a
battery disconnect or failure during an impact. The
ORC is secured to the floor panel transmission
tunnel below the instrument panel inside the vehi-
cle. The ORC cannot be repaired or adjusted and
must be replaced.
The ORC sends and/or receives PCI Bus mes-
sages with the Instrument Cluster (MIC), Body
Control Module (BCM), and Powertrain Control
Module (PCM). Diagnostic trouble codes will be set
if the communication with these modules is lost or
contains invalid information.
The microprocessor in the ORC monitors the
impact sensor signal and the airbag system electri-
cal circuits to determine the system readiness. The
ORC also monitors bus messages from both SIACM.
If the ORC detects a monitored system fault or
SIACM fault, it sends a message to the instrument
cluster via PCI bus to turn on the airbag warning
indicator. The ORC can set both active and stored
diagnostic trouble codes to aid in the diagnosing
system problems. See ORC/SIACM DIAGNOSTIC
TROUBLE CODES in this section.
The ORC has an internal accelerometer that
senses the rate of vehicle deceleration, which pro-vides verification of the direction and severity of an
impact. A pre-programmed decision algorithm in
the ORC microprocessor determines when the de-
celeration rate is severe enough to require airbag
system protection. The Occupant Restraint Control-
ler (ORC) also uses the driver and front passenger
seat belt switch status (buckled or unbuckled) as
inputs to determine the level of airbag deployment,
low, medium, or high as well as whether or not the
seat belt tensioners should deploy. The ORC also
uses the crash severity to determine the level of
driver and front passenger deployment, low me-
dium or high. When the programmed conditions are
met, the ORC sends an electrical signal to deploy
the appropriate airbag system components.WARNING: THE AIRBAG SYSTEM IS A
SENSITIVE, COMPLEX ELECTRO-
MECHANICAL UNIT. BEFORE ATTEMPTING
TO DIAGNOSE OR SERVICE ANY AIRBAG
SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENTS YOU MUST FIRST
DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE FURTHER SYSTEM
SERVICE. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IS ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY. NEVER STRIKE OR
KICK THE AIRBAG CONTROL MODULE, AS
IT CAN DAMAGE THE IMPACT SENSOR OR
AFFECT ITS CALIBRATION. IF AN AIRBAG
CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE
MUST BE SCRAPPED AND REPLACED WITH
A NEW UNIT.
The airbag warning lamp is the only point at
which the customer can observe symptoms of a
system malfunction. Whenever the ignition key is
turned to the run or start position, the MIC per-
forms a lamp check by turning the airbag warning
indicator on for 6-8 seconds. After the lamp check, if
the indicator turns on, it means that the ORC has
checked the system and found it to be free of
discernible malfunctions. If the lamp remains on,
there could be an active fault in the system or the
MIC lamp circuit may be internally shorted to
ground. If the lamp comes on and stays on for a
period longer than 6-8 seconds then goes off, there
is usually an intermittent problem in the system.
2
GENERAL INFORMATION