engine diesel CHRYSLER VOYAGER 2001 Service Manual

TABLE OF CONTENTS - Continued
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY..........................1036
DOSING PUMP - BLACK 2 WAY.........................................1036
DRIVER AIRBAG C1 - BROWN 2 WAY....................................1036
DRIVER AIRBAG C2 - BLACK 2 WAY.....................................1036
DRIVER BLEND DOOR ACTUATOR (ATC) - GRAY 2 WAY...................1037
DRIVER BLEND DOOR ACTUATOR (MTC) - GRAY 2 WAY...................1037
DRIVER DOOR LOCK SWITCH - BLACK 3 WAY...........................1037
DRIVER SEAT BELT SWITCH - WHITE 2 WAY.............................1037
DRIVER SEAT BELT TENSIONER-2WAY................................1038
ELECTRIC WIPER DE-ICER C1 - WHITE 2 WAY...........................1038
ELECTRIC WIPER DE-ICER C2 - WHITE 2 WAY...........................1038
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY.................1039
ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY.................1041
EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY...................1041
FRONT BLOWER MODULE C1 (ATC) - BLACK 4 WAY......................1042
FRONT BLOWER MODULE C2 (ATC) - BLACK 2 WAY......................1042
FRONT READING LAMPS/SWITCH - BLACK 6 WAY........................1042
GLOVE BOX LAMP - BLUE 2 WAY.......................................1042
HALO LAMP - BLUE 2 WAY.............................................1042
HEADLAMP SWITCH - BLACK 13 WAY...................................1043
HEADLAMP WASHER PUMP MOTOR (BUILT-UP-EXPORT) - BLACK 2 WAY. . . .1043
IGNITION SWITCH - BLACK 5 WAY......................................1043
INSTRUMENT CLUSTER - BLACK 13 WAY................................1044
INTELLIGENT POWER MODULE C1 - LT. GREEN/RED 20 WAY..............1044
INTELLIGENT POWER MODULE C2 - GREEN/BLUE 10 WAY................1045
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY........1045
INTELLIGENT POWER MODULE C3 (GAS) - NATURAL/RED 20 WAY..........1046
INTELLIGENT POWER MODULE C4 - BLUE 10 WAY.......................1046
INTELLIGENT POWER MODULE C5 - BLACK 4 WAY.......................1046
INTELLIGENT POWER MODULE C6 - NATURAL 10 WAY....................1047
INTELLIGENT POWER MODULE C7 - BLACK/RED 20 WAY..................1047
INTELLIGENT POWER MODULE C8 - ORANGE 10 WAY....................1048
INTELLIGENT POWER MODULE C9 - BLACK 10 WAY......................1048
LEFT B-PILLAR SWITCH - GRAY 3 WAY..................................1048
LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY.....1048
LEFT CYLINDER LOCK SWITCH - BLACK 2 WAY..........................1049
LEFT DOOR SPEAKER - BLACK/RED 6 WAY..............................1049
LEFT FOG LAMP - WHITE 2 WAY.......................................1049
LEFT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY.................1049
LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) -
BLACK 4 WAY........................................................1050
LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) -
BLACK 3 WAY........................................................1050
LEFT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY........1050
LEFT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY.............1050
LEFT HIGH BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY...............1051
LEFT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY.....................1051
LEFT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY...............1051
LEFT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY....................1051
LEFT POWER MIRROR - BLACK 12 WAY.................................1052
LEFT REAR PILLAR SPEAKER - BLACK 2 WAY............................1052
LEFT REAR READING LAMP (LUXURY) - GRAY 3 WAY.....................1052
LEFT REAR SPEAKER - BLACK/RED 6 WAY..............................1052
xxi

this type of system would only refer to this circuit.
A faulty speaker could not cause this DTC.
3.2.1 REMOTE RADIO CONTROLS
These radios can be controlled via remote radio
switches (optional). These switches are located on
the back side of the steering wheel. They control
mode, preset, seek up, seek down, volume up and
volume down functions.
These functions are inputs to the Body Control
Module and can be read with the DRBIIItunder
ªbody computerº. The switches are a multiplexed
signal to the BCM. The radio control MUX circuit is
a 5 volt line that is pulled to ground through
different value resistors built into the switches.
This causes a voltage drop to be seen by the BCM
and it sends a specific message to the radio on the
PCI Bus circuit. The radio then responses to the
message.
This circuit is fairly simple to troubleshoot. The
circuit must be complete from the switches in the
steering wheel to the BCM. The ground must be
complete so that the switches can cause the voltage
drop for the BCM to see. The circuit passes through
the clockspring so continuity through this devise
must be verified.
3.2.2 CD CHANGER
The new in-dash CD Changer is designed to fit
into the existing cubby bin in the center stack. This
new cartridge-less CD Changer is controlled by
your radio, and allows you to individually load up to
four discs at a time. However, due to its compact
design, the CD Changer can only carry out one
operation at a time. For example, you can not load
a new disc while playing another at the same time.
Each operation happens sequentially.
The radio unit installed with your system pro-
vides control over all features of the CD Changer
with the exception of the CD load and eject func-
tions, which are controlled by buttons located on the
front of the CD Changer. The radio also supplies the
power, ground, PCI Bus, left and right speaker
output thru a single DIN cable. All features you
would expect, such as Disc Up/Down, Track Up/
Down, Random and Scan are controlled by the
radio, which also displays all relevant CD Changer
information on the radio display.
The CD Changer contains a Load/Eject button
and an indicator light for each of the four disc
positions. The individual light indicates whether a
CD is currently loaded in that particular chamber of
the CD Changer. Pressing the individual Load/Eject
button for a particular chamber will eject a disc
currently present in that chamber. If the chamber iscurrently empty, actuating the Load/Eject button
will position that chamber to receive and load a new
disc in that chamber.
3.3 BODY CONTROL MODULE
The body control module (BCM) supplies vehicle
occupants with visual and audible information and
controls various vehicle functions. To provide and
receive information, the module is interfaced to the
vehicle's serial bus communications network (PCI).
This network consists of the powertrain control
module (PCM), the engine control module (ECM) -
diesel only, the transmission control module (TCM),
the mechanical instrument cluster (MIC), the front
control module (FCM), the occupant restraint con-
troller (ORC), the compass/mini-trip (CMTC), the
electronic vehicle information center (EVIC), the
controller antilock brake (CAB), the HVAC control
module (ATC & MTC), the power sliding door (Left
& Right) modules (PSD), the power liftgate module
(PLG), the Audio system, the side impact airbag
control (left & right) modules (SIACM), the memory
seat/mirror module (MSMM), the RKE/thatcham
alarm module and the sentry key immobilizer mod-
ule (SKIM). The BCM is operational when battery
power is supplied to the module.
The body control module provides the following
features:
²Power Door Locks
²Automatic Door Lock
²Door Lock Inhibit
²Central Locking (with VTSS Only)
²Battery Protection
²The BCM will automatically turn off all exterior
lamps after 3 minutes and all interior lamps after
15 minutes after the ignition is turned off, if they
are not turned off by the driver.
²Chime
²Compass/Minitrip Support
²Interior Lighting (Courtesy/Reading Lamps)
²BCM Diagnostic Reporting
²Electronic Liftgate Release (with Power Door
Locks)
²Exterior Lighting
²Power Folding Mirrors
²Remote Radio Controls
²Headlamp Time Delay (with/without Autohead-
lamps)
²Automatic Headlamps (with electrochromatic
mirror)
²Illuminated Entry
²Fade to Off
8
GENERAL INFORMATION

Turn Signal On: When the BCM detects a turn
signal input continuously for
1.0mile/0.6km and the vehicle
speed is greater than 15 mph/
24kph, the chime will sound until
the specific turn signal is can-
celled.
Dome Lights On: Ignition is in the lock position,
driver door ajar, and the dome
light switch is left in the on
position. The chime will sound
until one of the above conditions
is removed or until the battery
protection time of 15 minutes has
expired.
Low Oil Pres-
sure:The chime will sound when the
engine is operating and the oil
pressure drops below 4psi/27.5kPa.
Engine
Temperature
Critical:The chime will sound when the
engine is operating and the cool-
ant temperature exceeds 252ÉF/
122Cor 234É/112C(diesel).The
chime is continuous at 257ÉF/
125C and will chime for 4 min-
utes and stop if the temperature
drops below 255ÉF/123C.
Low Washer
FluidThe chime will sound when the
washer fluid drops below a spe-
cific level.
Warning Lamp
Announcement:A chime will sound to alert the
driver to scan the instrument
panel to see which warning lamp
is illuminated. The door/liftgate
ajar warning lamp will appear
without a chime if the vehicle is
running and a door or the liftgate
is opened. A chime will sound if
the door or liftgate is still open
and the vehicle speed is greater
than 4mph/6kph.
High-speed
warning Gulf
Coast Countries
(GCC) onlyThe chime will sound, acting as a
warning to the driver that the
vehicle speed has exceed
75mph62/120kph63.3.4.3 WARNING LAMP ANNOUNCEMENT
Low Fuel Lamp: The cluster will request a single
chime after the indicator is illu-
minated.
Volt Lamp: The cluster will request a single
chime after the indicator is illu-
minated.
Oil Pressure
Lamp:The cluster will request a single
chime after illuminating the in-
dicator above 450rpm vehicle op-
eration.
Headlight Out
Lamp:The cluster will request a single
chime after the indicator is illu-
minated.
Liftgate Ajar
Lamp:The BCM determines when to
chime for liftgate ajar.
Fasten Seat Belt
Lamp:The BCM will request five chimes
from the MIC when the ignition
is turned to the unlock/run/start
positions if the driver seat belt is
not buckled.
Check Engine
Lamp:The cluster will request a single
chime after the indicator is illu-
minated.
Low Washer
Fluid Lamp:The cluster will request a single
chime after the indicator is illu-
minated.
Engine Tempera-
ture Lamp:The cluster will request a single
chime when the indicator is first
illuminated at 252ÉF/122C.
3.4.4 OTHER CHIME ON CONDITIONS
Bulb Check: The chime will sound three times
during bulb check.
Programming of
an Additional
Key Fob:A double cluster chime will sound,
which signals that the program
mode has been initiated.
Programming for
Rolling Door
Locks:When the programming has been
completed, a single tone from the
chime system, will occur.
10
GENERAL INFORMATION

3.5 COMMUNICATION
The Programmable Communication Interface or
PCI Bus is a single wire multiplexed network capa-
ble of supporting binary encoded messages shared
between multiple modules. The PCI bus circuit is
identified as D25 and is white with a violet tracer.
Additional tracer colors may be added to the violet
in order to distinguish between different module
connections. The modules are wired in parallel.
Connections are made in the harness using splices.
One splice called the Diagnostic Junction Port,
serves as the ªHubº of the bus. The Diagnostic
Junction Port provides an access point to isolate
most of the modules on the bus in order to assist in
diagnosing the circuit. The following modules are
used on the RG:
²Body Control Module
²Front Control Module
²Occupant Restraint Controller
²Left Side Impact Airbag Control Module
²Right Side Impact Airbag Control Module
²Controller Antilock Brake
²Powertrain Control Module
²Engine Control Module - Diesel Only
²Radio
²CD Changer
²Transmission Control Module
²Automatic Temperature Control Module
²A/C Heater Control Module (MTC)
²Sentry Key Immobilizer Module
²RKE/Thatcham Alarm Module
²Memory Seat/Mirror Module
²Overhead Console
²Mechanical Instrument Cluster
²Left Sliding Door Control Module
²Right Sliding Door Control Module
²Power Liftgate Module
Each module provides its own bias and termina-
tion in order to transmit and receive messages. The
bus voltage is at zero volts when no modules are
transmitting and is pulled up to about seven and a
half volts when modules are transmitting.
The bus messages are transmitted at a rate
averaging 10800 bits per second. Since there is only
voltage present when the modules transmit and the
message length is only about 500 milliseconds, it is
ineffective to try and measure the bus activity witha conventional voltmeter. The preferred method is
to use the DRBIIItlab scope. The 12v square wave
selection on the 20-volt scale provides a good view of
the bus activity. Voltage on the bus should pulse
between zero and about seven and a half volts.
Refer to the following figure for some typical dis-
plays.
The PCI Bus failure modes are broken down into
two categories. Complete PCI Bus Communication
Failure and individual module no response. Causes
of complete PCI Bus Communication Failure in-
clude a short to ground or battery on the PCI
circuit. Individual module no response can be
caused by an open circuit at either the Diagnostic
Junction Port or the module, or an open battery or
ground circuit to the affected module.
Symptoms of a complete PCI Bus Communication
Failure would include but are not limited to:
²All gauges on the MIC stay at zero
²All telltales on MIC illuminate
²MIC backlighting at full intensity
²Dashed lines in the overhead console ambient
temperature display
²No response received from any module on the PCI
bus (except the PCM)
²No start (if equipped with Sentry Key Immobi-
lizer)
Symptoms of Individual module failure could
include any one or more of the above. The difference
would be that at least one or more modules would
respond to the DRBIIIt.
Diagnosis starts with symptom identification. If a
complete PCI Bus Communication Failure is sus-
pected, begin by identifying which modules the
vehicle is equipped with and then attempt to get a
response from the modules with the DRBIIIt.Ifany
modules are responding, the failure is not related to
the total bus, but can be caused by one or more
modules PCI circuit or power supply and ground
circuits. The DRBIIItmay display ªBUS +/- SIG-
NAL OPENº or ªNO RESPONSEº to indicate a
communication problem. These same messages will
be displayed if the vehicle is not equipped with that
particular module. The CCD error message is a
default message used by the DRBIIItand in no way
indicates whether or not the PCI bus is operational.
The message is only an indication that a module is
either not responding or the vehicle is not equipped.
11
GENERAL INFORMATION

the CPA is not properly engaged, a voltage on pin 38
will be interpreted as an unseated connector and a
fault will set.
Flash programming voltage Ð20 volt input on
pin 42. When a DRBIIItis connected and the
proper flash reprogramming sequence is selected,
the 20 volt signal will be applied through pin 42.
3.9 HEATING & A/C
3.9.1 AUTOMATIC TEMPERATURE
CONTROL (ATC)
3.9.1.1 CABIN HEATER
For vehicles equipped with a diesel engine, a
Cabin Heater is used in conjunction with the HVAC
system. The Cabin Heater is designed to supply the
vehicle's occupants with heat prior to the engine
reaching operating temperature. For additional in-
formation on this system, refer to Cabin Heater
under General Information and Diagnostic Proce-
dures in this manual.
3.9.1.2 SYSTEM OPERATION
The Automatic Temperature Control (ATC) sys-
tem provides fully adjustable three zone climate
control; Driver front zone, Passenger Front zone
and Rear zone. The following is a list of ATC
controls and features:
± a POWER button which allows the operator to
turn the system completely off.
± AUTO HIGH/LOW switch allows the operator
to select what rate (fan speed) the system will
provide the selected comfort level.
± DRIVER, REAR and PASSENGER rocker
switches to select desired temperature for each
zone.
± Recirculation button allows cooling air to be
recirculated which maximizes cooling ability.
± A/C select button allows the operator to turn
the A/C compressor off.
± Defroster button allows the operator to turn on
the defroster independently during automatic
control.
± Fan control rotary switch for selecting fan
speed.
± Mode rotary switch for selecting heating/
cooling direction.
± REAR SYSTEM rotary switch for activating
the Rear ATC Switch allowing intermediate
passenger control over rear climate control.
3.9.1.3 BLOWER MOTOR OPERATION
The Automatic Temperature Control (ATC) front
and rear blower control provides continuously vari-
able control of air flow rate to meet occupant
comfort requirements. Pulse width modulation of
the blower motor power allows the front and rear
blower to operate at any speed from off to full speed.
When front or rear blower operation is required, the
ATC sends a PCI Bus message to the Front Control
Module (FCM) requesting blower relay ON. The
FCM provides a ground for the front and rear
blower motor relay coils, activating both relays. The
front and rear blower relays provide 12 volts to
their respective blower motor power modules. Each
module provides a 12 volt blower motor control
signal to the ATC. The ATC provides a pulse width
modulated (duty-cycle) ground signal to this circuit
based on climate requirements. The higher voltage
on the signal circuit (less duty-cycle ground) the
lower the blower speed request. The lower voltage
on the signal circuit (more duty-cycle ground) the
higher the blower speed request.
3.9.1.4 INFRARED SENSORS
The ATC system uses infrared (I/R) sensors to
monitor and control oocupant comfort levels. This
sensing system replaces interior air temperature
and solar sensors which required complex control
programs to maintain occupant comfort levels. The
front I/R sensor is located in the instrument panel
center bezel outlet. The rear I/R sensor is located in
the rear overhead mounted ATC switch.
3.9.1.5 REAR ATC SWITCH
The rear ATC switch is mounted in the headliner.
The switch contains a rotary adjustment for fan
speed, a rotary adjustment for mode selection, a
push button switch for temperature selection and a
digital display of the selected temperature.
3.9.1.6 COOLDOWN TESTING
The ATC provides a feature referred to as a
Cooldown Test. This test is initiated using the
DRBIIItand is designed to check the performance
of the air conditioning system. The ATC will not
perform this test if the ambient air temperature is
below 12ÉC (53ÉF). During the test, the ATC com-
pares the ambient air temperature to the evapora-
tor temperature sensor. To pass the cooldown test,
the evap temperature sensor must drop -6ÉC (20ÉF)
below ambient temperature within 2 minutes of
start of test. At the completion of the cooldown test
the DRBIIItwill display one of the following mes-
sages indicating test outcome:
± Cooldown Test Passed
± Cooldown Test Failed
16
GENERAL INFORMATION

± Evap Temp Sensor Shorted
± Evap Temp Sensor Open
± A/C Pressure Too Low
± A/C Pressure Too High
± Invalid Conditions for Cooldown Test, Evap
Temperature Too Low
If a message other than Cooldown Test Passed
occurs, refer to the appropriate symptom for diag-
nosis.
3.9.1.7 ACTIVE AND STORED TROUBLE
CODES
The Automatic Temperature Control (ATC) is
capable of storing Active and Stored trouble codes.
Active codes indicate a current fault in the system.
Stored codes indicate that a problem has occurred
in the system, however is not currently present.
Active codes cannot be erased until the problem
causing the code has been repaired. At this time the
Active code is converted to a Stored code, which can
be erased using the DRBIIIt.
3.9.2 MANUAL TEMPERATURE CONTROL
3.9.2.1 SYSTEM AVAILABILITY
Depending on the model, either a Single-Zone Air
Conditioning System or a Dual-Zone Air Condition-
ing System is currently available in these vehicles.
3.9.2.2 CABIN HEATER
For Vehicles equipped with a diesel engine, a
Cabin Heater is used in conjunction with the HVAC
system. The Cabin Heater is designed to supply the
vehicle's occupants with heat prior to the engine
reaching operating temperature. For additional in-
formation on this system, refer to Cabin Heater
under General Information and Diagnostic Proce-
dures in this manual.
3.9.2.3 ZONE CONTROL ± SINGLE-ZONE
The Single-Zone Air Conditioning System main-
tains incoming air temperature, airflow, fan speed,
and fresh air intake for the entire vehicle from the
instrument panel mounted A/C ± Heater Control
Module. The full range of temperature that the
system can produce in any mode for the entire
vehicle is available by positioning the blend control
to the desired range.
3.9.2.4 ZONE CONTROL ± DUAL-ZONE
The Dual-Zone Air Conditioning System main-
tains incoming air temperature, airflow, fan speed,
and fresh air intake for the entire vehicle from the
instrument panel mounted A/C ± Heater ControlModule. In addition, this system provides com-
pletely independent side-to-side control of incoming
air temperature. The full range of temperature that
the system can produce in any mode is available on
either side of the vehicle by positioning the inde-
pendent driver and passenger blend controls to the
desired range.
3.9.2.5 AIR DISTRIBUTION
The HVAC unit has five fully adjustable instru-
ment panel outlets. Side-window demister outlets
in the instrument panel eliminate door ducts and
door-to-instrument panel seals. A single, central
mounted outlet delivers air for defrosting the wind-
shield. Air exhausters allow air entering at the
front of the vehicle to flow out the back to the rear
occupants. Mid-cabin comfort control directs only
cooling air flow to the intermediate seat occupants
through outlets at the rear of each front door trim
panel. Air is supplied to these outlets from the
instrument panel through ducts in the doors that
use molded seals at the instrument panel to prevent
air leakage. Wide outlets under the front seats with
directional dividers distribute heated air across the
floor to the intermediate seat occupants. Ducts in
the center of the vehicle under the carpet deliver air
from the HVAC unit to these outlets. Models
equipped with Dual-Zone A/C systems also include
a dust and odor air filter installed in the HAVC
housing.
3.9.2.6 DOOR ACTUATORS
The electric door actuators are a two-wire design.
Each door actuator uses a similar connector wired
directly to the A/C ± Heater Control Module. Single-
Zone systems have one blend door actuator, one
mode door actuator, and one recirculation door
actuator. Dual-Zone systems have two blend door
actuators, one mode door actuator, and one recircu-
lation door actuator. All of the door actuators are
accessible from the vehicle's interior.
3.9.2.7 DOOR ACTUATOR CONTROL
The A/C ± Heater Control Module knows the
number of operating actuator revolutions required
for full door travel as well as the number of actuator
commutator pulses per revolution. Using these pa-
rameters, the A/C ± Heater Control Module runs
the actuator for the number of commutator pulses
that correspond to the desired door position. To
maintain accuracy, the system recalibrates itself
periodically at known zero and full travel condi-
tions.
17
GENERAL INFORMATION

3.9.2.8 HVAC SYSTEM RELAYS
The Integrated Power Module (IPM) houses and
provides power to the A/C Clutch Relay and Front
Blower Motor Relay.
3.9.2.9 EVAPORATOR TEMPERATURE
SENSOR
An evaporator temperature sensor, located on the
A/C expansion valve under the hood, replaces the
previously used fin sensor.
3.9.2.10 A/C ± HEATER CONTROL
MODULE, SWITCH OPERATION
Power Switch
The Power Switch is a momentary contact switch.
The switch LED illuminates when the switch is on.
The Power Switch setting is remembered during
power down.
Rear Window Defogger Switch
The Rear Window Defogger Switch is a momen-
tary contact switch. Toggling the switch results in
the A/C ± Heater Control Module sending a change
of state message to the FCM to provide rear window
defogger activation or deactivation respectively.
The switch LED illuminates when the switch is on.
Recirculation Switch
The Recirculation Switch is a momentary contact
switch. Toggling the switch on results in the A/C ±
Heater Control Module signaling the actuator to
close the fresh-air door. Toggling the switch off
results in the A/C ± Heater Control Module signal-
ing the actuator to open the fresh-air door. The
switch LED illuminates when the switch is on.
When the Power Switch is off, the A/C ± Heater
Control Module closes the fresh-air door to prevent
outside air from entering the passenger compart-
ment. The recirculation mode will cancel whenever
defrost is requested. Pressing the Recirculation
Switch while in defrost mode will illuminate the
Recirculation Switch LED, but only while the but-
ton is pressed. Under this circumstance, the recir-
culation request will be denied and the fresh-air
door will remain in the fresh position. All door
positions are determined relative to the number of
commutator pulses required to provide full travel of
the door. On command, the A/C ± Heater Control
Module runs the actuator for the number of pulses
corresponding to the desired door position.
A/C Switch
The A/C Switch is a momentary contact switch.
Toggling the switch results in the A/C ± Heater
Control Module sending a change of state message
to the Powertrain Control Module (PCM ± gasoline)or Engine Control Module (ECM ± diesel) to provide
A/C compressor clutch activation or deactivation
respectively. The A/C ± Heater Control Module will
only provide this request if EVAP function is found
acceptable. The Power Switch must be on to make
the A/C switch active. The switch LED illuminates
when the switch is on. The A/C Switch setting is
remembered during power down.
Blower Switch
The rotary Blower Switch has five positions, Low,
M1, M2, M3, and High. The Power Switch must be
on to make the Blower Switch active. Toggling the
Power Switch results in the A/C ± Heater Control
Module sending a request to the FCM to provide
blower motor activation or deactivation respec-
tively.
Blend Switch ± Single Zone
The single rotary Blend Switch has multiple
detents to control the full range of temperature that
the system can produce in any mode. Rotating the
switch results in the A/C ± Heater Control Module
signaling the actuator to move the blend door. All
door positions are determined relative to the num-
ber of commutator pulses required to provide full
travel of the door. On command, the A/C ± Heater
Control Module runs the actuator for the number of
pulses corresponding to the desired door position.
Blend Switch ± Dual Zone
The dual sliding Blend Switches have multiple
detents to control the full range of temperature that
the system can produce an any mode. The upper
slide pot controls the driver-side blend door, while
the lower slide pot controls the passenger-side
blend door. Sliding the switch results in the A/C ±
Heater Control Module signaling the actuator to
move the blend door. All door positions are deter-
mined relative to the number of commutator pulses
required to provide full travel of the door. On
command, the A/C ± Heater Control Module runs
the actuator for the number of pulses corresponding
to the desired door position.
Mode Switch
The single rotary Mode Switch has 13 detents to
either direct airflow to the panel outlets, a mix of
floor and panel outlets, floor outlets, a mix of floor
and defrost outlets, or defrost outlets. Rotating the
switch results in the A/C ± Heater Control Module
signaling the actuator to move the mode door. All
door positions are determined relative to the num-
ber of commutator pulses required to provide full
travel of the door. On command, the A/C ± Heater
Control Module runs the actuator for the number of
pulses corresponding to the desired door position.
18
GENERAL INFORMATION

3.9.2.11 HVAC DIAGNOSTICS
The A/C ± Heater Control Module is fully addres-
sable with the DRBIIIt. Two of the Control Mod-
ule's diagnostic capabilities that the DRBIIItwill
actuate include the A/C Cooldown Test to test A/C
system performance and the HVAC Door Recalibra-
tion Test to determine actuator travel span. After
performing either test, the Control Module will
display one or more messages on the DRBIIIt
screen. The message will indicate either that the
HVAC system passed the test or that there is a fault
currently active in the HVAC system. The DRBIIIt
can also extract active and stored Diagnostic Trou-
ble Codes (DTCs) from the control module. Active
DTCs are faults that currently exit in the HVAC
system. Active DTCs cannot be erased until the
condition causing the code is repaired. Stored DTCs
are faults that occurred in the HVAC system since
the control module received the last ªclear diagnos-
tic infoº message.
3.10 CABIN HEATER
NOTE: The Cabin Heater, also known as the
Diesel Cabin Heater Assist (DCHA), will be
referred to as the DCHA throughout most of
the General Information and the Diagnostic
Procedures in this manual.
3.10.1 GENERAL SAFETY INFORMATION
WARNING: DO NOT OPERATE THE DCHA IN
AN ENCLOSED AREA SUCH AS A GARAGE
THAT DOES NOT HAVE EXHAUST
VENTILATION FACILITIES. ALWAYS VENT
THE DCHA's EXHAUST WHEN OPERATING
THE DCHA. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY OR DEATH.
WARNING: ALLOW THE DCHA ASSEMBLY
TO COOL BEFORE PERFORMING A COM-
PONENT INSPECTION/REPAIR/REPLACE-
MENT. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
WARNING: ALWAYS DISCONNECT THE
VEHICLE'S BATTERY PRIOR TO PER-
FORMING ANY TYPE OF WORK ON THE
DCHA. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY OR DEATH.WARNING: NEVER ATTEMPT TO REPAIR THE
DCHA HEATER MODULE OR ANY OF ITS
INTERNAL COMPONENTS. ALWAYS PER-
FORM DCHA COMPONENT REPLACEMENT
IN ACCORDANCE WITH THE SERVICE
INFORMATION. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
CAUTION: Do not actuate the DCHA Field
Mode Test with the engine off. Failure to
follow these instructions may result in
internal damage to the DCHA Heater Module.
CAUTION: Always Perform The Cabin Heater
Pre-Test Prior To Performing Any Other Cabin
Heater Test For The Test Result To Be Valid.
NOTE: Do not disconnect the vehicle's
battery or the DCHA's main power-supply
while the DCHA is in operation or in
run-down mode. Failure to follow these
instructions may result in excess emissions
from the DCHA Heater Module.
NOTE: Failure to prime the Dosing Pump
after draining the DCHA fuel line will prevent
DCHA heater activation during the first
attempt to start the heater. This will also set a
Diagnostic Trouble Code (DTC) in the DCHA
Control's memory. Do not perform the Dosing
Pump Priming Procedure if an attempt was
made to start the DCHA without priming the
Dosing Pump first. This will put excess fuel
in the DCHA Heater Module and cause smoke
to emit from the DCHA exhaust pipe when
heater activation occurs.
NOTE: Waxed fuel can obstruct the fuel line
and reduce flow. Check for the appropriate
winter grade fuel and replace as necessary.
3.10.2 COMPONENT DESCRIPTION AND
OPERATION
3.10.2.1 DCHA ASSEMBLY
The DCHA is a supplemental heater designed to
pre-heat the engine's coolant in order to supply the
vehicle's occupants with heat prior to the engine
reaching operating temperature. The DCHA assem-
bly mounts underneath the vehicle on the left side
floor pan near the front door opening. The DCHA
assembly connects to the vehicle's heater hoses and
has a fuel supply line that connects to the vehicle's
fuel tank.
19
GENERAL INFORMATION

WARNING: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL
COMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRBIIITSCREEN WHILE IN
MOTION. DO NOT HANG THE DRBIIITFROM
THE REAR VIEW MIRROR OR OPERATE IT
YOURSELF. HAVE AN ASSISTANT
AVAILABLE TO OPERATE THE DRBIIIT.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBIIIt(diagnostic read-out box)
Jumper wires
Ohmmeter
Voltmeter
Sentry Key Tester
Test Light
8310 Airbag System Load Tool
8443 SRS Airbag System Load Tool
Diagnostic Junction Port Tester 8339
6.0 GLOSSARY OF TERMS
ABSantilock brake system
ACMairbag control module
AECMairbag electronic control module
(ACM)
ASDMairbag system diagnostic module
(ACM)
AT Cautomatic temperature control
BCMbody control module
CABcontroller antilock brake
CMTCcompass/mini-trip computer
CPAconnector positive assurance
DABdriver airbag
DCHAdiesel cabin heater assist
(cabin heater)
DLCdata link connector
DTCdiagnostic trouble code
DRdriver
EBLelectric back lite (rear window de-
fogger)ECMEngine control module
EVICelectronic vehicle information center
FCMfront control module
GCCGulf Coast Countries
HVACheater ventilation, air conditioning
IPMintelligent power module
LDUlower drive unit
LHDLeft Hand Drive
MICmechanical instrument cluster
MTCmanual temperature control
MSMMmemory seat/mirror module
OBDon board diagnostics
ODOodometer
ORCoccupant restraint controller
PA Bpassenger airbag
PASSpassenger
PCIProgrammable Communication In-
terface (vehicle communication bus)
PCMpowertrain control module
PDCpower distribution center
PLGpower liftgate
PLGMpower liftgate module
PSDpower sliding door
PSDMpower sliding door module
PWMpulse width modulated
RHDRight Hand Drive
RKEremote keyless entry
SABseat airbag
SBTseat belt tensioner
SIACMside impact airbag control module
SKIMsentry key immobilizer module
SKISsentry key immobilizer system
SQUIBalso called initiator (located inside
airbag)
SRSsupplemental restraint system
TCMtransmission control module
VFDvacuum fluorescent display
VTSSvehicle theft security system
30
GENERAL INFORMATION

TEST ACTION APPLICABILITY
3WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
Turn the ignition on.
With the DRBIIIt, check for FCM and HVAC DTCs.
Does the DRBIIItdisplay any FCM or HVAC DTCs?All
Ye s®For FCM DTCs, return to the symptom list and choose the
symptom(s). Also, refer to Intelligent Power Module for related
symptom(s). For HVAC DTCs, refer to Heater & A/C for related
symptom(s).
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Go To 4
4WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
Start the engine.
Allow the engine to idle.
Turn the A/C - Heater Control Module's Power switch on.
Turn the Blower switch to the high speed position.
CAUTION: Do not activate the Diesel Cabin Heater Test with the engine off.
Failure to follow these instructions may result in internal damage to the
DCHA Heater Module.
NOTE: Do not disconnect the vehicle's battery or the DCHA's main power
supply while the DCHA is in operation or in run-down mode. Failure to
follow these instructions may result in excess emissions from the DCHA
during heater operation.
With the DRBIIItin HVAC, Systems Tests, select Diesel Cabin Heater Test and press
#1.
With the DRBIIItin HVAC, Systems Tests, Diesel Cabin Heater Test, read the Cabin
Heater Status.
Does the Status display: On?All
Ye s®Replace the FCM in accordance with the Service Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
333
CABIN HEATER
*CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE Ð
Continued