2001 CHRYSLER VOYAGER diesel

INTELLIGENT POWER MODULE C3 (GAS) - NATURAL/RED 20 WAYCAV CIRCUIT FUNCTION
1 Z115 20BK/OR (EATX)
(3.3L/3.8L)GROUND
1 Z115 18BK/OR (EATX)
(2.4L)GROUND
2 F1 18PK/WT (EATX) FCM OUTPUT (UNLOCK-RUN-START)
3 T751 18YL (EATX) IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT TRS REVERSE SENSE
5 T16 18YL/OR (EATX) TRANSMISSION CONTROL RELAY OUTPUT
6 T15 18YL/BR (EATX) TRANSMISSION CONTROL RELAY CONTROL
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
8 K31 18BR FUEL PUMP RELAY CONTROL
9 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A104 18YL/RD (EATX) FUSED B(+)
11 - -
12 - -
13 D25 18WT/VT (EATX) PCI BUS (EATX)
14 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 18BR/WT AUTOMATIC SHUTDOWN RELAY CONTROL
17 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
18 K173 18BR/VT RADIATOR FAN RELAY CONTROL
19 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
20 A109 18OR/RD FUSED B(+)
INTELLIGENT POWER MODULE C4 - BLUE 10 WAYCAV CIRCUIT FUNCTION
1 Z127 12BK/DG (GAS) GROUND
2 T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT
3 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
3 K342 16BR/WT (GAS) AUTOMATIC SHUTDOWN RELAY OUTPUT
4 F500 16DG/PK (EXCEPT
MTX))FUSED IGNITION SWITCH OUTPUT (RUN)
5- -
6 D25 16WT/VT (ANTILOCK
BRAKES)PCI BUS
7 A107 12TN/RD (ANTILOCK
BRAKES)FUSED B(+)
8 A111 12DG/RD (ANTILOCK
BRAKES)FUSED B(+)
9 A701 14BR/RD (GAS) B(+) (HAZARD FEED)
9 A710 14BR/RD (DIESEL) B(+) (HAZARD FEED)
10 - -
INTELLIGENT POWER MODULE C5 - BLACK 4 WAYCAV CIRCUIT FUNCTION
1 A1 4RD B(+)
2- -
3- -
4- -
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1046
CONNECTOR PINOUTS

INTELLIGENT POWER MODULE C8 - ORANGE 10 WAYCAV CIRCUIT FUNCTION
1 W3 12BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
2 T751 20YL (EXCEPT
BUILT-UP-EXPORT)IGNITION SWITCH OUTPUT (START)
2 N1 16DB/OR (GAS) FUEL PUMP RELAY OUTPUT
3 A108 18LG/RD FUSED B(+)
3 A108 18LG/RD (BUILT-UP-
EXPORT)FUSED B(+)
4 A103 18GY/RD FUSED B(+)
5 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
6 W4 12BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
7 C51 12LB/BR (AUTOMATIC
TEMPERATURE CONTROL)
(3 ZONE HVAC)FUSED REAR BLOWER MOTOR RELAY OUTPUT
8- -
9 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
10 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
INTELLIGENT POWER MODULE C9 - BLACK 10 WAYCAV CIRCUIT FUNCTION
1 A102 12WT/RD FUSED B(+)
2 F20 18PK/WT IGNITION SWITCH OUTPUT (RUN-START)
3 C15 12DB/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
4 A105 18DB/RD FUSED B(+)
5 L61 18WT/LG LEFT FRONT TURN SIGNAL DIVER
6 A701 16BR/RD FUSED B(+) (HAZARD)
6 A701 16BR/RD FUSED B(+) (HAZARD)
7 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT
8 F30 12PK/YL (POWER
WINDOWS)FUSED ACCESSORY RELAY OUTPUT
9 A115 12YL/RD (POWER
LIFTGATE)FUSED B(+)
10 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
LEFT B-PILLAR SWITCH - GRAY 3 WAYCAV CIRCUIT FUNCTION
1 Z61 20BK/DG GROUND
2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
3 G41 20VT/DG LEFT SLIDING DOOR PILLAR SWITCH MUX
LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAYCAV CIRCUIT FUNCTION
1 Q49 18TN/WT LEFT CINCH/RELEASE MOTOR UNLATCH DRIVER
2 Z249 18BK/WT GROUND
3 Q45 18OR/GY LEFT CINCH/RELEASE MOTOR CLUTCH DRIVER
4 Q47 18TN/GY LEFT CINCH/RELEASE MOTOR LATCH DRIVER
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CONNECTOR PINOUTS

FRONT CONTROL MODULE - BLACK 49 WAYCAV CIRCUIT FUNCTION
1 A1 B(+)
2 A1 B(+)
3 L43 LEFT LOW BEAM DRIVER
4 L34 RIGHT HIGH BEAM DRIVER
5 L33 LEFT HIGH BEAM DRIVER
6 L44 RIGHT LOW BEAM DRIVER
7 - NOT USED
8 Z117, Z118, Z343, Z344 GROUND
9 A1 B(+)
10 FCM 10 HORN RELAY CONTROL
11 FCM 11 NAME BRAND SPEAKER RELAY CONTROL
12 - SPARE
13 FCM 13 PARK LAMP RELAY CONTROL
14 FCM 14 FRONT WIPER ON/OFF RELAY CONTROL
15 C41 (DIESEL) CABIN HEATER ASSIST CONTROL
16 W7 FRONT WIPER PARK SWITCH SENSE
17 X3 HORN SWITCH SENSE
18 W1 WASHER FLUID LEVEL SWITCH SENSE
19 FCM 19 (GAS) IGNITION SWITCH OUTPUT (START)
20 A114 FUSED B(+) (I.O.D.)
21 L78 FUSED PARK LAMP RELAY OUTPUT (RIGHT)
22 D25 PCI BUS
23 G931 AMBIENT TEMPERATURE SENSOR RETURN
24 - SPARE
25 G31 AMBIENT TEMPERATURE SENSOR SIGNAL
26 L13 (RG) HEADLAMP ADJUST SIGNAL
27 F1, F2 FCM OUTPUT (UNLOCK-RUN-START)
28 F214 FCM OUTPUT (RUN-START) (SIACM)
29 F100 FCM OUTPUT (RUN) (ORC)
30 FCM 30 FRONT/REAR BLOWER MOTOR RELAY CONTROL
31 FCM 31 REAR WINDOW DEFOGGER RELAY CONTROL
32 FCM 32 (BUILT-UP-
EXPORT))HEADLAMP WASHER RELAY CONTROL
33 FCM 33 FRONT FOG LAMP RELAY CONTROL
34 FCM 34 FRONT WIPER HIGH/LOW RELAY CONTROL
35 FCM 35 ACCESSORY RELAY CONTROL (RUN-ACC)
36 B20 BRAKE FLUID LEVEL SWITCH SENSE
37 F20 IGNITION SWITCH OUTPUT (RUN-START)
38 A1 B(+)
39 T2 TRS REVERSE SENSE
40 T753 (DIESEL) IGNITION SWITCH OUTPUT (START)
41 L77 FUSED PARK LAMP RELAY OUTPUT (LEFT)
42 D23 FLASH PROGRAM ENABLE
43 Z116 GROUND
44 L50 PRIMARY BRAKE SWITCH SIGNAL
45 W10 FRONT WASHER PUMP MOTOR CONTROL
46 W20 REAR WASHER PUMP MOTOR CONTROL
47 K32 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL
48 F201 FCM OUTPUT (RUN-START) (ORC)
49 - NOT USED
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1067
CONNECTOR PINOUTS

10.5.1 PCM COMMUNICATION
10.5.2 ECM & CABIN HEATER ASSIST COMMUNICATION - DIESEL ONLY
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SCHEMATIC DIAGRAMS
10.5 COMMUNICATION (Continued)

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
3.1GENERAL DESCRIPTION............................................1
3.2FUNCTIONAL OPERATION...........................................1
3.2.1ECM ON-BOARD DIAGNOSTICS..............................1
3.2.2ECM OPERATING MODES...................................2
3.2.3MONITORED CIRCUITS......................................2
3.2.4SKIS OVERIVEW...........................................2
3.2.5SKIS ON-BOARD DIAGNOSTICS..............................2
3.2.6SKIS OPERATION...........................................2
3.3DIAGNOSTIC TROUBLE CODES......................................3
3.3.1HARD CODE...............................................3
3.3.2INTERMITTENT CODE.......................................3
3.3.3ECM DIAGNOSTIC TROUBLE CODES..........................3
3.3.4SKIM DIAGNOSTIC TROUBLE CODES.........................6
3.3.5HANDLING NO TROUBLE CODE PROBLEMS...................6
3.4USING THE DRBIIIT.................................................6
3.4.1DRBIIITDOES NOT POWER UP...............................6
3.4.2DISPLAY IS NOT VISIBLE....................................6
4.0 DISCLAIMERS, SAFETY, WARNINGS.......................................7
4.1DISCLAIMERS......................................................7
4.2SAFETY...........................................................7
4.2.1TECHNICIAN SAFETY INFORMATION..........................7
4.2.2VEHICLE PREPARATION FOR TESTING........................7
4.2.3SERVICING SUB-ASSEMBLIES...............................7
4.2.4DRBIIITSAFETY INFORMATION...............................7
4.3WARNINGS AND CAUTIONS.........................................8
4.3.1ROAD TEST WARNINGS.....................................8
4.3.2VEHICLE DAMAGE CAUTIONS...............................8
5.0 REQUIRED TOOLS AND EQUIPMENT......................................8
6.0 GLOSSARY OF TERMS...................................................8
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES............................9
COMMUNICATION
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY......................10
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY.....................11
DRIVEABILITY - DIESEL
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY............................13
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY POSITIVE AREA..............13
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH...............13
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW...............13
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TABLE OF CONTENTS - Continued
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW.............67
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW....70
P0335-CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION.........73
P0340-CKP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY.............75
P0340-CMP POSITION SENSOR CIRCUIT CMP/CKP SYNC FAILURE...........77
P0340-CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO HIGH.....80
P0340-CMP POSITION SENSOR CIRCUIT STATIC PLAUSIBILITY...............80
P0380-GLOW PLUG CIRCUIT A OPEN CIRCUIT.............................84
P0380-GLOW PLUG CIRCUIT A SHORT CIRCUIT............................84
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT............................87
P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT...........................90
P0480-FAN 1 CONTROL CIRCUIT OPEN CIRCUIT...........................92
P0480-FAN 1 CONTROL CIRCUIT SHORT CIRCUIT..........................94
P0481-FAN 2 CONTROL CIRCUIT OPEN CIRCUIT...........................96
P0481-FAN 2 CONTROL CIRCUIT SHORT CIRCUIT..........................98
P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH..................100
P0500-VEHICLE SPEED SENSOR HIGH LEVEL DURATION...................100
P0500-VEHICLE SPEED SENSOR PLAUSIBILITY...........................100
P0500-VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH..............100
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH.......104
P0520- OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY..................107
P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR LOW .110
P0530-A/C PRESSURE SENSOR CIRCUIT PLAUSIBILITY....................112
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH.......112
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW.......112
P0530-A/C PRESSURE SENSOR CIRCUIT SUPPLY VOLTAGE TOO HIGH OR
LOW.................................................................112
P0560-SYSTEM VOLTAGE TOO HIGH.....................................117
P0560-SYSTEM VOLTAGE TOO LOW.....................................120
*CHECKING THE CHARGING SYSTEM OPERATION - DIESEL................120
P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT.........................124
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE
DEVIATION TOO HIGH.................................................126
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE
DEVIATION TOO LOW..................................................126
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH . . .126
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO LOW. . . .126
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW. . . .126
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT.................126
P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT................126
P0620-GENERATOR FIELD CONTROL MALF UNSTABLE CURRENT...........126
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT OPEN CIRCUIT..........129
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT SHORT CIRCUIT.........131
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH..........133
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH..........133
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW..........136
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW..........136
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT........................139
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT......................142
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY........145
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE..........147
P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH
REDUNDANT CONTACT................................................149
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TABLE OF CONTENTS - Continued
SERIAL LINK EXTERNAL FAULT.........................................216
ROLLING CODE FAILURE...............................................218
VIN MISMATCH........................................................218
TRANSPONDER COMMUNICATION FAILURE..............................220
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE.............220
TRANSPONDER ID MISMATCH..........................................220
TRANSPONDER RESPONSE MISMATCH..................................220
VERIFICATION TESTS
VERIFICATION TESTS..................................................223
8.0 COMPONENT LOCATIONS..............................................227
8.1CONTROL MODULES.............................................227
8.2CONTROLS AND SOLENOIDS......................................227
8.3DATA LINK CONNECTOR..........................................227
8.4FUEL SYSTEM...................................................228
8.5RELAYS.........................................................228
8.6SENSORS.......................................................229
8.7SWITCHES......................................................230
9.0 CONNECTOR PINOUTS................................................231
A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY............................231
A/C PRESSURE SENSOR - GRAY 4 WAY..................................231
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY........231
BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY................231
BOOST PRESSURE SENSOR (DIESEL) - BLACK 4 WAY.....................232
BRAKE LAMP SWITCH - BLACK 6 WAY...................................232
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY...................232
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY...................232
CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY................232
DATA LINK CONNECTOR - BLACK 16 WAY................................233
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY...............................233
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY..................234
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY..................235
ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY..................236
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY.................236
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY.................237
ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY.............237
FUEL HEATER (DIESEL) - BLACK 2 WAY..................................237
FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY...........................237
FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAY...........................237
FUEL INJECTOR NO. 3 (DIESEL) - BLACK 2 WAY...........................238
FUEL INJECTOR NO. 4 (DIESEL) - BLACK 2 WAY...........................238
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY.......................238
FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY.....................238
GENERATOR - BLACK 2 WAY...........................................238
GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY.............................239
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY.........239
LEFT SPEED CONTROL SWITCH - WHITE 2 WAY..........................239
LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY..............................239
MASS AIR FLOW SENSOR (DIESEL) - ORANGE 5 WAY......................240
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TABLE OF CONTENTS - Continued
A/C COMPRESSOR CLUTCH RELAY......................................242
ECM/PCM RELAY (DIESEL).............................................242
FUEL HEATER RELAY (DIESEL)..........................................242
LIFT PUMP RELAY (DIESEL).............................................242
STARTER MOTOR RELAY...............................................242
RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY.............................242
RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAY.............................243
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY......................243
RADIATOR FAN RELAY NO. 2 (DIESEL) - BLUE 9 WAY......................243
RADIATOR FAN RELAY NO. 3 (DIESEL) - BLUE 9 WAY......................243
RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY.........................244
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY......................244
VEHICLE SPEED SENSOR (MTX/ATX) - BLACK 3 WAY......................244
WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY........................244
10.0 SCHEMATIC DIAGRAMS................................................245
10.12001 RG 2.5L TURBO DIESEL......................................245
11.0 CHARTS AND GRAPHS................................................247
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