2001 CHRYSLER VOYAGER service

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Install a substitute relay in place of the existing Front Blower Motor Relay.
With the DRB, erase DTCs.
Turn the ignition on.
With the DRB, read DTCs.
Did these DTCs reset?All
Yes, equipped with rear blower motor
Go To 3
Yes, not equipped with rear blower motor
Go To 4
No®Replace the original Front Blower Motor Relay.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Install a substitute relay in place of the existing Rear Blower Motor Relay.
With the DRB, erase DTCs.
Turn the ignition on.
With the DRB, read DTCs.
Did these DTCs reset?All
Ye s®Go To 4
No®Replace the original Rear Blower Motor Relay.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Remove the Front Control Module from the IPM.
Remove the Front Blower Motor Relay and the Rear Blower Motor Relay, if equipped,
from the IPM.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the Front Blower Motor Relay
connector cavity 85.
Is the test light illuminated?All
Ye s®Replace the Intelligent Power Module (IPM) in accordance with
the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the Front Control Module (FCM) in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
545
HEATING & A/C
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT ÐContinued

Symptom List:
LOOPBACK FAILURE (ACTIVE) - MANUAL A/C
LOOPBACK TEST FAILURE (ACTIVE) - MANUAL A/C
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be LOOPBACK FAILURE (ACTIVE)
- MANUAL A/C.
When Monitored and Set Condition:
LOOPBACK FAILURE (ACTIVE) - MANUAL A/C
When Monitored: When the A/C - Heater Control Module executes an internal loopback
test.
Set Condition: If the A/C - Heater Control Module fails to send a message, or none of the
expected messages arrive for 5 seconds, an internal loopback test is executed. If the
internal loopback test fails, the DTC will set.
LOOPBACK TEST FAILURE (ACTIVE) - MANUAL A/C
When Monitored: When the A/C - Heater Control Module executes an internal loopback
test.
Set Condition: If the A/C - Heater Control Module fails to send a message, or none of the
expected messages arrive for 5 seconds, an internal loopback test is executed. If the
internal loopback test fails, the DTC will set.
POSSIBLE CAUSES
ADDITIONAL CODE(S) PRESENT
A/C - HEATER CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read HVAC DTCs.
Does the DRBIIItdisplay any additional HVAC DTCs?All
Ye s®Return to the symptom list and choose the symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
546
HEATING & A/C

Symptom List:
NO PCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C
PCM COMMUNICATION FAILURE (ACTIVE) - MANUAL A/C
VEHICLE ODOMETER FAILURE (ACTIVE) - MANUAL A/C
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be NO PCM MESSAGE RECEIVED
(ACTIVE) - MANUAL A/C.
When Monitored and Set Condition:
NO PCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C
When Monitored: With the ignition on.
Set Condition: This DTC will set if the A/C - Heater Control Module does not see any
messages from the PCM for more than 5 seconds.
PCM COMMUNICATION FAILURE (ACTIVE) - MANUAL A/C
When Monitored: With the ignition on.
Set Condition: This DTC will set if the A/C - Heater Control Module does not receive the
Fuel message from the PCM for more than 5 seconds.
VEHICLE ODOMETER FAILURE (ACTIVE) - MANUAL A/C
When Monitored: With the ignition on.
Set Condition: This DTC will set if the A/C - Heater Control Module does not receive the
Vehicle Odometer message from the PCM for more than 5 seconds.
POSSIBLE CAUSES
MESSAGE NOT RECEIVED
ATTEMPT TO COMMUNICATE WITH THE PCM/ECM
PCI BUS CIRCUIT OPEN
POWERTRAIN/ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, enter HVAC, System Tests then PCM Monitor.
Does the DRBIIItdisplay: PCM is active on BUS?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Go To 2
547
HEATING & A/C

TEST ACTION APPLICABILITY
2 Turn the ignition on.
With the DRBIIIt, attempt to communicate with the PCM/ECM.
Was the DRBIIItable to communicate with the PCM/ECM?All
Ye s®Go To 3
No®Refer to Communication for the related symptom(s)
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the PCM C2/ECM C1 harness connector.
Connect the diagnostic junction port tester #8339 to the diagnostic junction port.
NOTE: Do not connect the tester to the DRB.
Measure the resistance of the PCI Bus circuit between the diagnostic junction port
tester and the PCM C2/ECM C1 connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace and program the Powertrain/Engine Control Module in
accordance with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the PCI Bus circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
548
HEATING & A/C
NO PCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Turn the A/C - Heater Control, rear blower control switch knob to the Rear position.
Set the Rear Blower Rear Control, blend control switch knob to the full cold position.
Disconnect the Rear A/C - Heater Unit harness connector.
Connect a 12-volt Test Light between the Rear Mode Door Driver circuit and the Rear
Common Door Driver circuit (Cavity 2) at the Rear A/C - Heater Unit harness
connector (HVAC side).
Turn the ignition on.
While monitoring the test light, manually sweep the Rear Blower Rear Control, rear
blend control switch knob very slowly from full cold to full hot.
While monitoring the test light, manually sweep the Rear Blower Rear Control, rear
blend control switch knob very slowly from full hot to full cold.
Does the test light start to flash and stay flashing through the entire range?All
Ye s®Go To 5
No®Go To 7
5 Turn the ignition off.
Disconnect the Rear A/C - Heater Unit harness connector.
Remove the Rear Mode Door Actuator from the Rear A/C - Heater Housing.
Disconnect the Rear Mode Door Actuator harness connector.
Measure the resistance of the Rear Mode Door Driver circuit between the Rear Mode
Door Actuator harness connector and the Rear A/C - Heater Unit harness connector
(plenum side).
Measure the resistance of the Rear Common Door Driver circuit between the Rear
Mode Door Actuator harness connector and the Rear A/C - Heater Unit harness
connector (Cavity 2) (plenum side).
Is the resistance below 5.0 ohms for both circuits?All
Ye s®Go To 6
No®Repair the circuit with the resistance above 5 ohms for an open.
Perform BODY VERIFICATION TEST - VER 1.
6 Turn the ignition off.
Remove the applicable door actuator (Rear Blend, Rear Mode) from the Rear A/C -
Heater Housing.
Disconnect the door actuator harness connector.
By hand, attempt to rotate the door actuator in both directions.
Did the door actuator turn in either direction?All
Ye s®Replace the door actuator in accordance with the Service Infor-
mation.
Perform BODY VERIFICATION TEST - VER 1.
No®Inspect the Rear A/C - Heater Housing for missing and broken
actuator linkage. Inspect the linkage and the actuator for broken
and missing teeth. Check the doors for binding and loss of full
range. Repair as necessary.
Perform BODY VERIFICATION TEST - VER 1.
551
HEATING & A/C
REAR BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Remove the applicable door actuator (Rear Blend, Rear Mode) from the Rear A/C -
Heater Housing.
Disconnect the door actuator harness connector.
Measure the resistance of the applicable door driver circuit (Rear Blend, Rear Mode)
between the A/C - Heater Control Module C1 harness connector and the door actuator
harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Repair the applicable door driver circuit (Rear Blend, Rear Mode)
for an open.
Perform BODY VERIFICATION TEST - VER 1.
8 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Remove the applicable door actuator (Rear Blend, Rear Mode) from the Rear A/C -
Heater Housing.
Disconnect the door actuator harness connector.
Measure the resistance of the Common Door Driver circuit between the applicable
door actuator harness connector (Rear Blend, Rear Mode) and the A/C - Heater
Control Module C1 harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the Common Door Driver circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
552
HEATING & A/C
REAR BLEND CALIBRATION FAULT - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance of the Rear Temperature Return circuit between the A/C -
Heater Control Module C1 harness connector and the Rear Blower Rear Control
Switch C2 harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 4
No®Repair the Rear Temperature Return circuit between the A/C -
Heater Control Module C1 harness connector and the Rear
Blower Rear Control Switch C2 harness connector for an open.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
NOTE: Make sure that the Rear Blower Rear Control Switch C2 harness
connector is connected to the Rear Blower Rear Control Switch.
Measure the resistance of the Rear Blower Rear Control Switch, Rear Blend
Potentiometer as follows:
Turn the Rear Blend knob to full hot.
Measure the resistance between the 5 Volt Supply circuit and the Rear Temperature
Feedback Signal circuit at the A/C - Heater Control Module C1 harness connector.
The resistance should be approximately 2K ohms.
Slowly rotate the Rear Blend knob from full hot to full cold while viewing the DVOM.
The reading should change fluidly from approximately 2K to 10.5K ohms.
Turn the Rear Blend knob to full hot.
Measure the resistance between the 5 Volt Supply circuit and the Rear Temperature
Return circuit at the A/C - Heater Control Module C1 harness connector. The
resistance should be approximately 10.9K ohms.
Slowly rotate the Rear Blend knob from full hot to full cold while viewing the DVOM.
The reading should stay steady at approximately 10.9K ohms.
Turn the Rear Blend knob to full hot.
Measure the resistance between the Rear Temperature Return circuit and the Rear
Temperature Feedback Signal circuit at the A/C - Heater Control Module C1 harness
connector. The resistance should be approximately 10.2K ohms.
Slowly rotate the Rear Blend knob from full hot to full cold while viewing the DVOM.
The reading should change fluidly from approximately 10.2K to 1.9K ohms.
Are all of the resistance measurements as specified?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Replace the Rear Blower Rear Control Switch in accordance with
the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
554
HEATING & A/C
REAR BLEND POT CIRCUIT OPEN (ACTIVE) - MANUAL A/C ÐContinued

TEST ACTION APPLICABILITY
5 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance of the Rear Temperature Feedback Signal circuit between the
A/C - Heater Control Module C1 harness connector and the Rear Blower Rear Control
Switch C2 harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the Rear Temperature Feedback Signal circuit between
the A/C - Heater Control Module C1 harness connector and the
Rear Blower Rear Control C2 harness connector for an open.
Perform BODY VERIFICATION TEST - VER 1.
6 Turn the ignition off.
Disconnect the A/C - Heater Control Module C1 harness connector.
Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the resistance of the 5 Volt Supply circuit between the A/C - Heater Control
Module C1 harness connector and the Rear Blower Rear Control Switch C2 harness
connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the A/C - Heater Control Module in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No®Repair the 5 Volt Supply circuit between the A/C - Heater Control
Module C1 harness connector and the Rear Blower Rear Control
C2 harness connector for an open.
Perform BODY VERIFICATION TEST - VER 1.
555
HEATING & A/C
REAR BLEND POT CIRCUIT OPEN (ACTIVE) - MANUAL A/C ÐContinued