2001 CHRYSLER VOYAGER sensor

POWERTRAIN CONTROL MODULE C2 (2.4L/3.3L/3.8L) - GRAY/GRAY 40 WAYCAV CIRCUIT FUNCTION
41 V37 18VT SPEED CONTROL SWITCH SIGNAL
42 C18 18LB/BR A/C PRESSURE SENSOR SIGNAL
43 K900 18DB/DG SENSOR GROUND
44 F888 18BR/PK 8 VOLT SUPPLY
45 - -
46 A109 18OR/RD FUSED B(+)
47 - -
48 K40 18BR/LG (2.4L) IDLE AIR CONTROL NO. 3 DRIVER
49 K60 18VT/LG (2.4L) IDLE AIR CONTROL NO. 2 DRIVER
49 K39 18VT/DG (3.3L/3.8L) IDLE AIR CONTROL NO. 1 DRIVER
50 Z131 18BK/DG GROUND
51 K141 18DB/YL OXYGEN SENSOR 1/2 SIGNAL
52 - -
53 - -
54 - -
55 - -
56 V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL
57 K39 18VT/DG (2.4L) IDLE AIR CONTROL NO. 1 DRIVER
57 K60 18VT/LG (3.3L/3.8L) IDLE AIR CONTROL NO. 2 DRIVER
58 K59 18BR/DG (2.4L) IDLE AIR CONTROL NO. 4 DRIVER
59 D25 18WT/VT PCI BUS
60 - -
61 F855 18PK/YL 5 VOLT SUPPLY
62 B29 18DG/WT SECONDARY BRAKE SWITCH SIGNAL
63 T10 18DG/LG (EATX) TORQUE MANAGEMENT REQUEST SENSE
64 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
65 D21 18WT/BR SCI TRANSMIT
66 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL
67 K51 18BR/WT AUTOMATIC SHUTDOWN RELAY CONTROL
68 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL
69 - -
70 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE
71 - -
72 K107 18VT/WT (EXCEPT
BUILT-UP-EXPORT)LEAK DETECTION PUMP SWITCH SENSE
73 K173 18BR/VT RADIATOR FAN RELAY CONTROL
74 K31 18BR FUEL PUMP RELAY CONTROL
75 D20 18WT/LG SCI RECEIVE
76 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41)
77 K106 18VT/LB (EXCEPT
BUILT-UP-EXPORT)LEAK DETECTION PUMP SOLENOID CONTROL
78 K54 18DB/WT (ATX) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
79 - -
80 V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL
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RIGHT INSTRUMENT PANEL SPEAKER - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 X154 20GY/YL RIGHT FRONT I/P SPEAKER (+)
2 X156 20GY/LB RIGHT FRONT I/P SPEAKER (-)
RIGHT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 Z344 16BR GROUND
2 L44 16WT RIGHT LOW BEAM DRIVER
RIGHT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 Z344 16BR GROUND
2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT)
RIGHT POWER MIRROR - BLACK 12 WAYCAV CIRCUIT FUNCTION
1 P174 20TN/LB (BUILT-UP-
EXPORT)RIGHT FOLDING MIRROR UNFOLD DRIVER
2- -
3- -
4 P68 20TN/YL (MEMORY) RIGHT MIRROR HORIZONTAL POSITION SIGNAL
5 P66 20TN/LG (MEMORY) RIGHT MIRROR SENSOR GROUND
6 P67 20TN/OR (MEMORY) RIGHT MIRROR VERTICAL POSITION SIGNAL
7 P160 20TN/LG (BUILT-UP-
EXPORT/LHD)PASSENGER FOLDING MIRROR RELAY OUTPUT
7 P159 20TN/DG (BUILT-UP-
EXPORT/RHD)DRIVER FOLDING MIRROR FOLD DRIVER
8 Z216 20BK/DB GROUND
9 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
10 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
11 P72 20TN/GY RIGHT MIRROR VERTICAL DRIVER
12 P74 20TN/DB RIGHT MIRROR HORIZONTAL DRIVER
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1080
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THATCHAM ALARM MODULE C1 (UNITED KINGDOM) - BLACK 16 WAYCAV CIRCUIT FUNCTION
1- -
2- -
3 G22 20YL VTSS INDICATOR SUPPLY
4 D23 20WT/BR FLASH PROGRAM ENABLE
5 D97 20WT/OR SIREN SIGNAL OUTPUT
6 D96 20WT/LB SIREN SIGNAL CONTROL
7 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 G944 20LB/BR SIREN SIGNAL RETURN
9- -
10 - -
11 G922 20GY VTSS INDICATOR DRIVER
12 - -
13 D25 20WT/VT PCI BUS
14 - -
15 L91 20WT/DB HAZARD SWITCH SENSE
16 A600 20RD/LB SIREN SUPPLY
THATCHAM ALARM MODULE C2 (UNITED KINGDOM) - WHITE 4 WAYCAV CIRCUIT FUNCTION
1 18BK/LB REAR INTRUSION SENSOR SIGNAL
4 18BK/WT SENSOR GROUND
2 18BK/LB FRONT INTRUSION SENSOR SIGNAL
3 18BK/WT SENSOR GROUNDC
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1084
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TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAYCAV CIRCUIT FUNCTION
1 T1 18DG/LB TRS T1 SENSE
2- -
3 T3 18DG/DB TRS T3 SENSE
4- -
5- -
6 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
7 D21 18WT/BR SCI TRANSMIT
8 T751 18YL IGNITION SWITCH OUTPUT (START)
9 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18DG/LG TORQUE MANAGEMENT REQUEST SENSE
11 F1 18PK/WT FCM OUTPUT (UNLOCK-RUN-START)
12 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
13 T13 18DG/VT SPEED SENSOR GROUND
14 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
15 T15 18YL/BR TRANSMISSION CONTROL RELAY CONTROL
16 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
17 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
18 - -
19 T19 18YL/DB 2-4 SOLENOID CONTROL
20 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
41 T41 18DG/GY (3.3L/3.8L) TRS T41 SENSE
41 T41 18YL/DB (2.4L) TRS T41 SENSE
42 T42 18DG/YL TRS T42 SENSE
43 D25 18WT/VT PCI BUS
44 - -
45 - -
46 D16 18WT/OR SCI RECEIVE
47 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
48 - -
49 - -
50 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
51 K900 18DB/DG SENSOR GROUND
52 T52 18DG/WT INPUT SPEED SENSOR SIGNAL
53 Z132 16BK/YL GROUND
54 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T55 18YL/VT (AUTOSTICK) AUTOSTICK/OVERDRIVE OFF MUX INPUT
56 A104 18YL/RD FUSED B(+)
57 Z133 16BK/LG GROUND
58 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL
59 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
60 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
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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
3.1TEVES MARK 20 SYSTEM DESCRIPTION..............................1
3.2TRACTION CONTROL SYSTEM (TCS) DESCRIPTION....................1
3.3SYSTEM COMPONENTS.............................................2
3.3.1ABS AND BRAKE WARNING INDICATORS.......................2
3.3.2CONTROLLER ANTILOCK BRAKE (CAB)........................2
3.3.3HYDRAULIC CONTROL UNIT..................................3
3.3.4SWITCHES/SENSORS........................................3
3.3.5SYSTEM INITIALIZATION.....................................3
3.3.6DIAGNOSTIC MODE.........................................4
3.4DIAGNOSTIC TROUBLE CODES......................................4
3.5DRBIIITERROR MESSAGES AND BLANK SCREEN......................4
3.5.1DRBIIITDOES NOT POWER UP................................4
3.5.2DISPLAY IS NOT VISIBLE.....................................4
4.0 DISCLAIMERS, SAFETY, WARNINGS.......................................5
4.1DISCLAIMERS......................................................5
4.2SAFETY...........................................................5
4.2.1TECHNICIAN SAFETY INFORMATION...........................5
4.2.2VEHICLE PREPARATION FOR TESTING.........................5
4.2.3SERVICING SUB-ASSEMBLIES................................5
4.2.4DRBIIITSAFETY INFORMATION...............................5
4.3WARNINGS........................................................6
4.3.1VEHICLE DAMAGE WARNINGS................................6
4.3.2ROAD TESTING A COMPLAINT VEHICLE........................6
4.4DIAGNOSIS........................................................6
5.0 REQUIRED TOOLS AND EQUIPMENT......................................6
6.0 GLOSSARY OF TERMS...................................................7
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES............................9
BRAKES (CAB)
BUS SYSTEM COMMUNICATION FAILURE.................................10
CAB INTERNAL FAILURE................................................11
CLUSTER LAMP FAILURE................................................12
LEFT FRONT SENSOR CIRCUIT FAILURE..................................14
LEFT REAR SENSOR CIRCUIT FAILURE...................................14
RIGHT FRONT SENSOR CIRCUIT FAILURE.................................14
RIGHT REAR SENSOR CIRCUIT FAILURE..................................14
LEFT FRONT WHEEL SPEED SIGNAL FAILURE.............................17
LEFT REAR WHEEL SPEED SIGNAL FAILURE..............................19
PUMP CIRCUIT FAILURE................................................21
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE............................24
i

TABLE OF CONTENTS - Continued
RIGHT REAR WHEEL SPEED SIGNAL FAILURE.............................26
SYSTEM OVERVOLTAGE................................................28
SYSTEM UNDERVOLTAGE...............................................30
VALVE POWER FEED FAILURE...........................................32
*BRAKE LAMP SWITCH..................................................35
*TRAC OFF INDICATOR NEVER/ALWAYS ON...............................36
*TRAC ON INDICATOR NEVER/ALWAYS ON................................39
VERIFICATION TESTS
VERIFICATION TESTS...................................................40
8.0 COMPONENT LOCATIONS...............................................41
8.1CONTROLLER ANTILOCK BRAKE (CAB)..............................41
8.2DATA LINK CONNECTOR...........................................41
8.3FUSES...........................................................42
8.4TRACTION CONTROL SWITCH......................................42
8.4.1TRACTION CONTROL INDICATORS...........................43
8.5WHEEL SPEED SENSORS..........................................43
8.5.1FRONT....................................................43
8.5.2REAR.....................................................44
8.5AWHEEL SPEED SENSOR CONNECTORS..............................44
8.5A.1FRONT....................................................44
8.5A.2REAR.....................................................45
8.6BRAKE LAMP SWITCH.............................................45
9.0 CONNECTOR PINOUTS.................................................47
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY..........................47
DATA LINK CONNECTOR - WHITE 16 WAY.................................47
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY............................48
INTELLIGENT POWER MODULE C4 - GRAY 10 WAY.........................48
LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY......................48
LEFT FRONT WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE)-2WAY..49
LEFT REAR WHEEL SPEED SENSOR - BLACK 2 WAY........................49
LEFT REAR WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE)-2WAY ...49
FUSES (IPM)...........................................................51
PUMP MOTOR CONNECTOR-2WAY.....................................52
RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY......................52
RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
(SENSOR SIDE)-2WAY.................................................52
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY......................52
RIGHT REAR WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE)-2WAY..53
TRACTION CONTROL SWITCH - BLACK 2 WAY.............................53
10.0 SCHEMATIC DIAGRAMS.................................................55
TEVES MARK 20 ANTILOCK BRAKE SYSTEM........................55
ii

The cycling of the build and decay valves is
similar to the ABS except that they work to control
wheel spin by applying brakes. ABS function is to
control wheel skid by releasing brakes.
Two pressure relief valves allow excess fluid vol-
ume to return to the reservoir when not used by the
build/decay cycles. These are required because the
pump supplies more volume than the traction con-
trol system requires.
If at any time the brake pedal is applied during a
traction control cycle, the brake lamp switch will
trigger the CAB to switch off the traction control.
The traction control system will be enabled at
each ignition cycle. It may be turned off by depress-
ing the Traction Control Switch. The traction con-
trol system function lamp will illuminate ªTRAC
OFFº immediately upon depressing the traction
control switch button. Only the ªTRACº portion of
the ªTRAC OFFº indicator will illuminate during a
traction control event. If the CAB calculates that
the brake temperatures are high, the traction con-
trol system will become inoperative until a time-out
period has elapsed. When in this thermal protection
mode, the traction control ªTRAC OFFº lamp will
illuminate; however, a fault will not be registered.
3.3 SYSTEM COMPONENTS
²controller antilock brake (CAB)
²vacuum booster
²master cylinder
²ABS integrated electronic control module/
hydraulic control unit (HCU), valve block assem-
bly: 8 valve solenoids (4 inlet valves, 4 outlet
valves, 2 accumulators) 1 motor, 2 pump
²ABS integrated electronic control module with
traction control same as above but has 10 valve
solenoids.
²4 wheel speed sensor/tone wheel assemblies
²ABS warning indicator
²fuses and wiring harness
²fluid reservoir
²TRAC/TRAC OFF indicator
3.3.1 ABS AND BRAKE WARNING
INDICATORS
The amber ABS warning indicator is located in
the instrument cluster. It is used to inform the
driver that the antilock function has been turned
off. The ABS warning indicator is controlled by the
CAB. The CAB controls the lamp with a command
over the PCI bus.
The ABS Warning Indicator will remain lit during
every key cycle until a circuit or component fault is
repaired and the CAB no longer detects the fault.After repair of a sensor signal fault or a pump motor
fault, the CAB must sense all four wheels at 25
km/h (15 mph) before it will extinguish the ABS and
TRAC OFF Indicators.
The Instrument Cluster will illuminate the ABS
Warning Indicator if it loses communication with
the CAB.
The red BRAKE warning indicator is also located
in the instrument cluster. It can be activated in
several ways. Application of the parking brake or a
low fluid signal from the fluid level switch located in
the master cylinder reservoir will cause the indica-
tor to come on.
3.3.2 CONTROLLER ANTILOCK BRAKE
(CAB)
The Controller Antilock Brake (CAB) is a
microprocessor-based device that monitors wheel
speeds and controls the antilock functions. The
CAB contains two microprocessors that receive
identical sensor signals and then independently
process the information. The results are then com-
pared to make sure that they agree. Otherwise, the
CAB will turn off the antilock and turn on the ABS
amber warning indicator.
The primary functions of the CAB are to:
²detect wheel locking tendencies
²control fluid pressure modulation to the brakes
during antilock stop
²monitor the system for proper operation
²manage traction control functions
²provide communication to the DRBIIItwhile in
diagnostic mode
²store diagnostic information in non-volatile memory
The CAB continuously monitors the speed of each
wheel. When a wheel locking tendency is detected,
the CAB will command the appropriate valve to
modulate brake fluid pressure in its hydraulic unit.
Brake pedal position is maintained during an an-
tilock stop by being a closed system with the use of
2 accumulators. The CAB continues to control pres-
sure in individual hydraulic circuits until a wheel
locking tendency is no longer present. The CAB
turns on the pump motor during an antilock stop.
The antilock brake system is constantly moni-
tored by the CAB for proper operation. If the CAB
detects a system malfunction, it can disable the
antilock system and turn on the ABS warning
indicator. If the antilock function is disabled, the
system will revert to standard base brake system
operation.
The CAB inputs include the following:
²diagnostic communication
²four wheel speed sensors
2
GENERAL INFORMATION

²three power feeds: valves, pump and microproces-
sor
²brake switch
²traction control switch
The CAB outputs include the following:
²ABS warning indicator actuation
²12 volts power to wheel speed sensors
²eight valves
²ten valves with traction control
²diagnostic communication
²PCI bus communication
²traction control lamp illumination
3.3.3 HYDRAULIC CONTROL UNIT
The hydraulic control unit (HCU) contains the
valve block assembly, two accumulators, and pump/
motor assembly. The HCU is attached to the CAB.
Valve Block Assembly:The valve block assem-
bly contains valves with four inlet valves and four
outlet valves. The inlet valves are spring-loaded in
the open position and the outlet valves are spring
loaded in the closed position. During an antilock
stop, these valves are cycled to maintain the proper
slip ratio for each wheel. If a wheel detects slip, the
inlet valve is closed to prevent and further pressure
increase. Then the outlet valve is opened to release
the pressure to the accumulators until the wheel is
no longer slipping. Once the wheel is no longer
slipping, the outlet valve is closed and the inlet
valve is opened to reapply pressure. If the wheel is
decelerating within its predetermined limits (prop-
er slip ratio), the inlet valve will close to hold the
pressure constant. On vehicles which are equipped
with a traction control system, there are two addi-
tional valves that isolate the master cylinder and
rear wheels. During a traction control event the
brakes are applied to reduce wheel slippage.
Pump Motor Assembly:The pump motor as-
sembly provides the extra amount of fluid needed
during antilock braking. The pump is supplied fluid
that is released to the accumulators when the outlet
valve is opened during an antilock stop. The pump
is also used to drain the accumulator circuits after
the antilock stop is complete. The pump is operated
by an integral electric motor. This DC-type motor is
controlled by the CAB. The CAB may turn on the
pump motor when an antilock stop is detected. The
pump continues to run during the antilock stop and
is turned off after the stop is complete. Under some
conditions, the pump motor will run to drain the
accumulators during the next drive off. The CAB
monitors the pump motor operation internally.
Accumulators:The accumulators provide tem-
porary fluid storage during an antilock stop and are
drained by the pump motor.
3.3.4 SWITCHES/SENSORS
Master Cylinder:The master cylinder is a stan-
dard tandem compensating port design for ABS and
non ABS systems. Traction control vehicles use a
dual center port master cylinder. For proper trac-
tion control operation the standard master cylinder
must not be used.
A fluid level switch is located in the master
cylinder fluid reservoir. The switch closes when a
low fluid level is detected. The fluid level switch
turns on the brake warning indicator by grounding
the indicator circuit. This switch does not disable
the ABS system.
Wheel Speed Sensors and Tone Wheels:One
active wheel speed sensor (WSS) is located at each
wheel and sends a small signal to the control
module (CAB). This signal is generated when a
toothed sensor ring (tone wheel) passes by a station-
ary wheel speed sensor. The CAB converts the
signals into digital signals for each wheel.
Because of internal circuitry, correct wheel speed
sensor function cannot be determined by a continu-
ity or resistance check through the sensor.
The front wheel speed sensor is attached to a boss
in the steering knuckle. The tone wheel is an
integral part of the front axle shaft. The rear speed
sensor is mounted though the bearing cover and the
rear tone wheel is an integral part of the rear
bearing hub. The wheel speed sensor air gap is not
adjustable. Refer to the service manual for wheel
speed sensor air gap and resistance specifications.
The four wheel speed sensors are serviced indi-
vidually. The front tone wheels are serviced as an
assembly with the outer constant velocity (C.V.)
joint housing. The rear tone wheels are serviced as
an assembly.
Correct antilock system operation is dependent
on tone wheel speed signals from the wheel speed
sensors. The vehicle's wheels and tires should all be
the same size and type to generate accurate signals.
In addition, the tires should be inflated to the
recommended pressure for optimum system opera-
tion. Variation in wheel and tire size or significant
variations in inflation pressure can produce inaccu-
rate wheel speed signals; however, the system will
continue to function when using the mini-spare.
3.3.5 SYSTEM INITIALIZATION
System initialization starts when the key is
turned to ªrunº. At this point, the CAB performs a
complete self-check of all electrical components in
the antilock systems.
Between 8-17 km/h (5-10 mph), a dynamic test is
performed. This will momentarily cycle the inlet
and outlet valves, check wheel speed sensor cir-
cuitry, and run the pump motor at 25 km/h (15
mph). The CAB will try to test the pump motor. If
3
GENERAL INFORMATION