2004 Chrysler Grand Voyager Service & Repair Manual

TABLE OF CONTENTS 1.0 INTRODUCTION .........................................................1 1.1 SYSTEM COVERAGE ...............................................1 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1 2.0 IDENTIFICATION OF SYSTEM .............................................1 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1 3.1 ADJUSTABLE PEDALS SYSTEM ......................................2 3.2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND OCCUPANT CLASSIFICATION SYSTEM ................................2 3.2.1 DRIVER AIRBAG............................................3 3.2.2 CLOCKSPRING.............................................4 3.2.3 PASSENGER AIRBAG .......................................4 3.2.4 SEAT BELT TENSIONER (SBT) ................................6 3.2.5 SEAT BELT SWITCHES (SBS).................................6 3.2.6 DRIVER KNEE BLOCKER AIRBAG .............................6 3.2.7 FRONT AND SIDE IMPACT SENSOR ...........................6 3.2.8 OCCUPANT CLASSIFICATION SYSTEM ........................6 3.2.9 SPECIAL TOOLS............................................9 3.2.10 DIAGNOSTIC TROUBLE CODES ..............................9 3.2.10.1 ACTIVE CODES ............................................9 3.2.10.2 STORED CODES ...........................................9 3.3 AUDIO SYSTEM ...................................................10 3.3.1 NAVIGATION RADIO........................................10 3.3.2 REMOTE RADIO CONTROLS ................................10 3.3.3 CD CHANGER .............................................11 3.3.4 DVD/CD CHANGER ........................................11 3.4 BODY CONTROL MODULE ..........................................11 3.5 CHIME WARNING SYSTEM .........................................12 3.5.1 CHIME PRIORITY ..........................................12 3.5.2 CHIME ON CONDITIONS....................................12 3.5.3 WARNING LAMP ANNOUNCEMENT ..........................13 3.5.4 OTHER CHIME ON CONDITIONS.............................13 3.6 COMMUNICATION .................................................13 3.7 DOOR AJAR SYSTEM ..............................................15 3.8 EXTERIOR LIGHTING SYSTEM ......................................15 3.8.1 HEADLAMP POWER .......................................15 3.8.2 HEADLAMP SWITCH .......................................15 3.8.3 PARK LAMP RELAY ........................................15 3.8.4 FOG LAMP RELAY .........................................15 3.8.5 FOG LAMPS ..............................................15 3.8.6 EXTERIOR LIGHTING BATTERY SAVER .......................16 3.8.7 AUTO HEADLAMPS ........................................16 3.9 FRONT CONTROL MODULE .........................................16 3.9.1 CONTROLLED POWER FEEDS ..............................16 3.9.2 RELAY CONTROLS ........................................17 3.9.3 ELECTRICAL INPUTS ......................................18 3.10 HEATING & A/C SYSTEM ...........................................19 3.10.1 AUTOMATIC TEMPERATURE CONTROL (ATC) .................19 3.10.1.1 MODULE USAGE ..........................................19 3.10.1.2 SYSTEM AVAILABILITY .....................................19 i

TABLE OF CONTENTS - Continued 3.10.1.3 SYSTEM CONTROLS .......................................19 3.10.1.4 SYSTEM REVISIONS .......................................20 3.10.1.5 SYSTEM DIAGNOSTICS ....................................20 3.10.2 MANUAL TEMPERATURE CONTROL (MTC) ....................21 3.10.2.1 MODULE USAGE ..........................................21 3.10.2.2 SYSTEM AVAILABILITY .....................................21 3.10.2.3 SYSTEM CONTROLS .......................................22 3.10.2.4 SYSTEM REVISIONS .......................................23 3.10.2.5 SYSTEM DIAGNOSTICS ....................................23 3.11 CABIN HEATER ...................................................24 3.11.1 GENERAL SAFETY INFORMATION ...........................24 3.11.2 COMPONENT DESCRIPTION AND OPERATION ................25 3.11.2.1 DCHA ASSEMBLY..........................................25 3.11.2.2 COMBUSTION AIR FAN .....................................25 3.11.2.3 BURNER HOUSING ........................................25 3.11.2.4 BURNER INSERT ..........................................25 3.11.2.5 CONTROL UNIT/HEAT EXCHANGER ..........................25 3.11.2.6 DOSING PUMP ............................................25 3.11.3 OPERATION ..............................................25 3.11.3.1 VENTING THE DCHA’S EXHAUST ............................25 3.11.3.2 ACTIVATION ..............................................26 3.11.3.3 HEATING .................................................27 3.11.3.4 DEACTIVATION ............................................27 3.11.3.5 SYSTEM REVISIONS .......................................27 3.11.4 DIAGNOSTICS ............................................27 3.12 INSTRUMENT CLUSTER ............................................27 3.12.1 INSTRUMENT CLUSTER SELF TEST .........................28 3.12.2 MESSAGE CENTER (EXPORT ONLY) .........................28 3.13 INTERIOR LIGHTING ...............................................28 3.13.1 COURTESY LAMP CONTROL ................................28 3.13.2 ILLUMINATED ENTRY ......................................28 3.13.3 INTERIOR LIGHTING BATTERY SAVER .......................28 3.14 MEMORY SYSTEM.................................................28 3.14.1 POWER SEAT .............................................29 3.14.2 MEMORY MIRROR .........................................29 3.15 OVERHEAD CONSOLE .............................................29 3.15.1 VEHICLE INFORMATION DISPLAY............................30 3.15.2 TRAVELER DISPLAY FUNCTIONS ............................31 3.15.3 SETTING MAGNETIC ZONE VARIANCE .......................31 3.15.4 COMPASS CALIBRATION ...................................32 3.15.5 SELF-CHECK DIAGNOSTICS ................................32 3.15.6 AMBIENT TEMPERATURE SENSOR ..........................32 3.15.7 AMBIENT TEMPERATURE SENSOR FAULT CODES .............33 3.15.8 HOMELINKT UNIVERSAL TRANSMITTER ......................33 3.15.9 TIRE PRESSURE MONITORING SYSTEM (TPMS)...............33 3.15.9.1 TRAINING THE SKREEM....................................33 3.15.9.2 PRESSURE THRESHOLDS ..................................34 3.15.9.3 ACTIVE FAULT AND SYSTEM ALERTS ........................34 3.16 PARK ASSIST SYSTEM .............................................34 3.17 POWER DOOR LOCK SYSTEM ......................................34 3.17.1 DOOR LOCK INHIBIT .......................................34 3.17.2 AUTOMATIC DOOR LOCKS .................................35 3.17.3 REMOTE KEYLESS ENTRY (RKE) ............................35 ii

TABLE OF CONTENTS - Continued 3.17.3.1 PANIC FUNCTION .........................................35 3.17.3.2 ROLLING CODE ...........................................35 3.17.3.3 PROGRAMMABLE DOOR LOCK FEATURES ...................35 3.18 POWER FOLDING MIRRORS ........................................36 3.19 POWER LIFTGATE SYSTEM .........................................36 3.19.1 POWER LIFTGATE .........................................36 3.19.2 DIAGNOSTIC FEATURES ...................................36 3.19.3 SYSTEM INHIBITORS ......................................36 3.20 POWER SLIDING DOOR SYSTEM ....................................36 3.20.1 POWER SLIDING DOOR ....................................36 3.20.2 DIAGNOSTIC FEATURES ...................................37 3.20.3 SYSTEM INHIBITORS ......................................37 3.21 REAR WINDOW DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE (IF EQUIPPED) .......................................................37 3.22 TELECOMMUNICATIONS ...........................................37 3.22.1 HANDS FREE PHONE ......................................37 3.23 VEHICLE THEFT SECURITY SYSTEM .................................38 3.23.1 THATCHAM ALARM SYSTEM (EXPORT ONLY) .................38 3.24 WIPER SYSTEM ...................................................38 3.24.1 FRONT WIPER ............................................38 3.24.2 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............39 3.24.3 PULSE WIPE ..............................................39 3.24.4 PARK AFTER IGNITION OFF.................................39 3.24.5 WIPE AFTER WASH ........................................39 3.24.6 REAR WIPER .............................................39 3.24.7 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............39 3.24.8 WIPE AFTER WASH ........................................39 3.25 USING THE DRBIIIT ................................................39 3.26 DRBIIIT ERROR MESSAGES ........................................39 3.27 DRBIIIT DOES NOT POWER UP (BLANK SCREEN)......................39 3.28 DISPLAY IS NOT VISIBLE ...........................................39 4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................40 4.1 DISCLAIMERS.....................................................40 4.2 SAFETY ..........................................................40 4.2.1 TECHNICIAN SAFETY INFORMATION .........................40 4.2.2 VEHICLE PREPARATION FOR TESTING .......................40 4.2.3 SERVICING SUB-ASSEMBLIES ..............................40 4.2.4 DRBIIIT SAFETY INFORMATION .............................40 4.3 WARNINGS .......................................................41 4.3.1 VEHICLE DAMAGE WARNINGS ..............................41 4.3.2 ROAD TESTING A COMPLAINT VEHICLE......................41 5.0 REQUIRED TOOLS AND EQUIPMENT .....................................41 6.0 GLOSSARY OF TERMS..................................................41 iii

TABLE OF CONTENTS - Continued 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ..........................43 ADJUSTABLE PEDALS PEDAL SENSOR OPEN/SHORTED TO GROUND.............................44 PEDAL SENSOR SHORTED TO BATTERY ..................................47 PEDAL SW STUCK FORWARD ............................................50 PEDAL SW STUCK REARWARD ..........................................52 *CAN’T ADJUST PEDALS ................................................54 *CAN’T SET/RECALL MEMORY POSITIONS .................................59 AIRBAG ACCELEROMETER 1 ....................................................61 ACCELEROMETER 2 ....................................................61 INTERNAL 1 ...........................................................61 INTERNAL 2 ...........................................................61 INTERNAL 3 ...........................................................61 INTERNAL 4 ...........................................................61 MODULE NOT CONFIGURED FOR OCS ....................................61 OUTPUT DRIVER 1 .....................................................61 OUTPUT DRIVER 2 .....................................................61 STORED ENERGY FIRING 1..............................................61 AIRBAG WARNING INDICATOR OPEN .....................................64 AIRBAG WARNING INDICATOR SHORT ....................................64 CALIBRATION MISMATCH................................................67 CLUSTER MESSAGE MISMATCH .........................................69 DRIVER KNEE BLOCKER CIRCUIT OPEN ..................................71 DRIVER KNEE BLOCKER CIRCUIT SHORT .................................74 DRIVER KNEE BLOCKER SHORT TO BATTERY .............................77 DRIVER KNEE BLOCKER SHORT TO GROUND .............................80 DRIVER SEAT BELT SWITCH CIRCUIT OPEN ...............................83 DRIVER SEAT BELT SWITCH SHORTTO BATTERY ..........................86 DRIVER SEAT BELT SWITCH SHORT TO GROUND ..........................89 DRIVER SEAT BELT SWITCH SHORT TOGETHER ...........................91 DRIVER SEAT BELT TENSIONER CIRCUIT OPEN ............................93 DRIVER SEAT BELT TENSIONER CIRCUIT SHORT ..........................96 DRIVER SEAT BELT TENSIONER SHORT TO BATTERY.......................99 DRIVER SEAT BELT TENSIONER SHORT TO GROUND ......................102 DRIVER SQUIB 1 CIRCUIT OPEN ........................................105 DRIVER SQUIB 1 CIRCUIT SHORT .......................................108 DRIVER SQUIB 1 SHORT TO BATTERY ...................................111 DRIVER SQUIB 1 SHORT TO GROUND ...................................114 DRIVER SQUIB 2 CIRCUIT OPEN ........................................117 DRIVER SQUIB 2 CIRCUIT SHORT .......................................120 DRIVER SQUIB 2 SHORT TO BATTERY ...................................123 DRIVER SQUIB 2 SHORT TO GROUND ...................................126 INTERROGATE OCM ...................................................129 LEFT CURTAIN OR SEAT SQUIB CIRCUIT OPEN ...........................131 LEFT CURTAIN OR SEAT SQUIB CIRCUIT SHORT ..........................134 LEFT CURTAIN OR SEAT SQUIB SHORTTO BATTERY ......................137 LEFT CURTAIN OR SEAT SQUIB SHORT TO GROUND ......................140 LEFT FRONT IMPACT SENSOR INTERNAL 1 ...............................143 NO LEFT FRONT IMPACT SENSOR COMMUNICATION ......................143 LEFT SIDE IMPACT SENSOR 1 INTERNAL 1 ...............................147 iv

TABLE OF CONTENTS - Continued NO LEFT SIDE IMPACT SENSOR 1 COMMUNICATION.......................147 LEFT SIDE IMPACT SENSOR 2 INTERNAL 1 ...............................151 NO LEFT SIDE IMPACT SENSOR 2 COMMUNICATION.......................151 LEFT SIDE IMPACT SENSOR 3 INTERNAL 1 ...............................155 NO LEFT SIDE IMPACT SENSOR 3 COMMUNICATION.......................155 LOSS OF IGNITION RUN - START ........................................159 ORC RUN - START DRIVER OPEN .......................................159 ORC RUN - START DRIVER OVER CURRENT ..............................159 ORC RUN - START DRIVER OVER TEMP ..................................159 ORC RUN - START DRIVER OVER VOLT ..................................159 ORC RUN - START DRIVER SHORT TO GROUND ..........................159 LOSS OF IGNITION RUN ONLY ..........................................165 ORC RUN ONLY DRIVER OPEN..........................................165 ORC RUN ONLY DRIVER OVER CURRENT ................................165 ORC RUN ONLY DRIVER OVER TEMP ....................................165 ORC RUN ONLY DRIVER OVER VOLT ....................................165 ORC RUN ONLY DRIVER SHORT TO GROUND.............................165 NO CLUSTER MESSAGE ...............................................171 NO OCM MESSAGE ....................................................173 NO ODOMETER MESSAGE .............................................175 NO ORC MESSAGE ....................................................178 NO PCI LOOPBACK ....................................................181 PCI BUS SHORT TO BATTERY...........................................181 PCI BUS SHORT TO GROUND ...........................................181 NO PCI TRANSMISSION ................................................187 NO RIGHT FRONT IMPACT SENSOR COMMUNICATION .....................189 RIGHT FRONT IMPACT SENSOR INTERNAL 1 .............................189 NO RIGHT SIDE IMPACT SENSOR 1 COMMUNICATION .....................193 RIGHT SIDE IMPACT SENSOR 1 INTERNAL 1 ..............................193 NO RIGHT SIDE IMPACT SENSOR 2 COMMUNICATION .....................197 RIGHT SIDE IMPACT SENSOR 2 INTERNAL 1 ..............................197 NO RIGHT SIDE IMPACT SENSOR 3 COMMUNICATION .....................201 RIGHT SIDE IMPACT SENSOR 3 INTERNAL 1 ..............................201 OCCUPANT CLASSIFICATION MODULE DATATRANSFER ERROR ............205 OCCUPANT CLASSIFICATION UNDETERMINED ............................207 RE-ZERO INCOMPLETE ................................................207 SEAT NOT CALIBRATED ................................................207 SYSTEM VERIFICATION REQUIRED - OCSVR .............................207 OCM CONFIGURATION MISMATCH.......................................212 PASSENGERAIRBAG OFF INDICATOR CIRCUIT SHORT TO BATTERY ........214 PASSENGER AIRBAG OFF INDICATOR CIRCUIT SHORT TO GROUND.........217 PASSENGER BTS OPEN ................................................222 PASSENGER BTS SHORT TO BATTERY...................................222 PASSENGER BTS SHORT TO GROUND ...................................222 PASSENGER BTS SHORT TOGETHER ....................................222 PASSENGER PRESSURE SENSOR OPEN .................................226 PASSENGER PRESSURE SENSOR SHORT GROUND .......................226 PASSENGER PRESSURE SENSOR SHORT TO BATTERY ....................226 PASSENGER PRESSURE SENSOR SHORT TOGETHER .....................226 PASSENGER SEAT BELT SWITCH CIRCUIT OPEN ..........................229 PASSENGER SEAT BELT SWITCH SHORTTO BATTERY .....................231 PASSENGER SEAT BELT SWITCH SHORTTO GROUND .....................234 PASSENGER SEAT BELT SWITCH SHORT TOGETHER ......................237 v

TABLE OF CONTENTS - Continued PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN ......................239 PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT .....................242 PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY .................245 PASSENGER SEAT BELT TENSIONER SHORT TO GROUND .................248 PASSENGER SEAT SENSOR FLUID LEVEL TOO LOW.......................250 PASSENGER SQUIB 1 CIRCUIT OPEN ....................................251 PASSENGER SQUIB 1 CIRCUIT SHORT ...................................254 PASSENGER SQUIB 1 SHORT TO BATTERY ...............................257 PASSENGER SQUIB 1 SHORT TO GROUND ...............................260 PASSENGER SQUIB 2 CIRCUIT OPEN ....................................263 PASSENGER SQUIB 2 CIRCUIT SHORT ...................................266 PASSENGER SQUIB 2 SHORT TO BATTERY ...............................269 PASSENGER SQUIB 2 SHORT TO GROUND ...............................272 POWER SUPPLY VOLTAGE LOW.........................................275 RIGHT CURTAIN OR SEAT SQUIB CIRCUIT OPEN ..........................278 RIGHT CURTAIN OR SEAT SQUIB CIRCUIT SHORT .........................281 RIGHT CURTAIN OR SEAT SQUIB SHORTTO BATTERY .....................284 RIGHT CURTAIN OR SEAT SQUIB SHORT TO GROUND .....................287 VEHICLE BODY STYLE MISMATCH .......................................290 VIN MISMATCH ........................................................293 *AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES ...............297 AUDIO ALL OUTPUTS SHORT .................................................298 CASSETTE PLAYER INOP ..............................................301 CD MECHANICAL FAILURE .............................................301 NO PCI TRANSMISSION ................................................301 REAR TRANSMITTER FAILURE ..........................................301 *AM/FM SWITCH INOPERATIVE ..........................................301 *ANY STATION PRESET SWITCH INOPERATIVE ............................301 *BALANCE INOPERATIVE ...............................................301 *CD EJECT SWITCH INOPERATIVE.......................................301 *EQUALIZER INOPERATIVE .............................................301 *FADER INOPERATIVE .................................................301 *FF/RW SWITCH INOPERATIVE ..........................................301 *HOUR/MINUTE SWITCHES INOPERATIVE ................................301 *PAUSE/PLAY SWITCH INOPERATIVE ....................................301 *PWR SWITCH INOPERATIVE ...........................................301 *SCAN SWITCH INOPERATIVE ..........................................301 *SEEK SWITCH INOPERATIVE ...........................................301 *SET SWITCH INOPERATIVE ............................................301 *TAPE EJECT SWITCH INOPERATIVE.....................................301 *TIME SWITCH INOPERATIVE ...........................................301 *TUNE SWITCH INOPERATIVE...........................................301 CD CHANGER MECHANICAL FAILURE ....................................303 CD CHANGER READ FAILURE...........................................304 CD CHANGER TEMPERATURE HIGH .....................................305 CD PLAY FAILURE .....................................................306 CD READ FAILURE ....................................................307 CD TEMPERATURE HIGH ...............................................308 GPS ANTENNA NOT CONNECTED .......................................309 LOW VOLTAGE LEVEL .................................................310 NBS OUTPUT 1 OPEN ..................................................311 vi

TABLE OF CONTENTS - Continued NBS OUTPUT 2 OPEN ..................................................311 NBS OUTPUT 1 SHORT TO BATT ........................................313 NBS OUTPUT 2 SHORT TO BATT ........................................313 NO ANTENNA CONNECTION ............................................315 NO COMMUNICATION WITH BCM ........................................316 POWER AMP SHUTDOWN ..............................................317 RADIO AND NAV GPS ANTENNA NOT CONNECTED ........................320 REMOTE RADIO SWITCH STUCK ........................................321 *REMOTE RADIO CONTROLS INOPERATIVE ..............................324 AUTOMATIC TEMPERATURE CONTROL AC PRESSURE TOO HIGH (ACTIVE)......................................327 AC PRESSURE TOO HIGH (STORED).....................................328 DRIVER BLEND DOOR NOT RESPONDING (STORED) ......................328 DRIVER BLEND DOOR RANGE TOO LARGE (STORED) .....................328 DRIVER BLEND DOOR TRAVEL TOO SMALL (STORED) .....................328 EVAP TEMP SENSOR OPEN (STORED) ...................................328 EVAP TEMP SENSOR SHORTED (STORED) ...............................328 FRONT IR SENSOR AND CONTROL HEAD MISMATCH (STORED) .............328 FRONT IR SENSOR CHANGE TOO LARGE (STORED) .......................328 FRONT IR SENSOR HIGH (STORED) .....................................328 FRONT IR SENSOR LOW (STORED) ......................................328 FRONT IR SENSOR NOT CALIBRATED (STORED) ..........................328 FRONT KEYBOARD COMMUNICATION FAULT (STORED) ....................328 FRONT KEYBOARD FAULT (STORED) ....................................328 FRONT MODE DOOR NOT RESPONDING (STORED) ........................328 FRONT MODE DOOR TRAVEL TOO LARGE (STORED) ......................328 FRONT MODE DOOR TRAVEL TOO SMALL (STORED) ......................328 PASS BLEND DOOR NOT RESPONDING (STORED).........................328 PASS BLEND DOOR TRAVEL TOO LARGE (STORED) .......................328 PASS BLEND DOOR TRAVEL TOO SMALL (STORED) .......................328 PCI BUS SHORTED HIGH (STORED) .....................................328 PCI BUS SHORTED LOW (STORED) ......................................328 REAR BLEND DOOR NOT RESPONDING (STORED) ........................328 REAR BLEND DOOR RANGE TOO LARGE (STORED) .......................328 REAR BLEND DOOR TRAVEL TOO SMALL (STORED) .......................328 REAR FAN POT OPEN (STORED) ........................................328 REAR FAN POT SHORTED (STORED) ....................................328 REAR KEYBOARD FAULT (STORED) .....................................328 REAR MODE DOOR NOT RESPONDING (STORED) .........................328 REAR MODE DOOR TRAVEL TOO LARGE (STORED) .......................328 REAR MODE DOOR TRAVEL TOO SMALL (STORED) ........................328 REAR MODE POT OPEN (STORED) ......................................328 REAR MODE POT SHORTED (STORED) ..................................328 RECIRC DOOR NOT RESPONDING (STORED) .............................328 RECIRC DOOR TRAVEL TOO LARGE (STORED)............................328 RECIRC DOOR TRAVEL TOO SMALL (STORED) ............................328 COOLDOWN TEST FAILED ..............................................335 DRIVER BLEND DOOR NOT RESPONDING (ACTIVE) .......................337 DRIVER BLEND DOOR TRAVEL TOO LARGE (ACTIVE) ......................339 DRIVER BLEND DOOR TRAVEL TOO SMALL (ACTIVE) ......................340 EEPROM CHECKSUM ERROR (ACTIVE) ..................................342 EVAP TEMP SENSOR OPEN (ACTIVE) ....................................343 vii

TABLE OF CONTENTS - Continued EVAP TEMP SENSOR SHORTED (ACTIVE) ................................347 FRONT AND REAR BLOWER OUTPUT 1 OPEN ............................349 FRONT AND REAR BLOWER OUTPUT 2 OPEN ............................349 FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT ...................350 FRONT AND REAR BLOWER OUTPUT 2 SHORT TO BATT ...................350 FRONT IR SENSOR AND CONTROL HEAD MISMATCH (ACTIVE) ..............351 FRONT IR SENSOR CHANGE TOO LARGE (ACTIVE) ........................351 FRONT IR SENSOR HIGH (ACTIVE) ......................................351 FRONT IR SENSOR LOW (ACTIVE) .......................................351 FRONT IR SENSOR NOT CALIBRATED (ACTIVE) ...........................352 FRONT KEYBOARD FAULT (ACTIVE) .....................................352 FRONT KEYBOARD COMMUNICATION FAULT (ACTIVE) .....................357 FRONT MODE DOOR NOT RESPONDING (ACTIVE) .........................358 FRONT MODE DOOR TRAVEL TOO LARGE (ACTIVE) .......................360 FRONT MODE DOOR TRAVEL TOO SMALL (ACTIVE) .......................361 INVALID CONDITIONS FOR COOLDOWN TEST, EVAPTEMPERATURE TOO LOW .................................................................362 PASS BLEND DOOR NOT RESPONDING (ACTIVE)..........................365 PASS BLEND DOOR TRAVEL TOO LARGE (ACTIVE) ........................367 PASS BLEND DOOR TRAVEL TOO SMALL (ACTIVE) ........................368 PCI BUS SHORTED HIGH (ACTIVE) ......................................370 PCI BUS SHORTED LOW (ACTIVE) .......................................370 REAR BLEND DOOR NOT RESPONDING (ACTIVE) .........................371 REAR BLEND DOOR TRAVEL TOO LARGE (ACTIVE) ........................373 REAR BLEND DOOR TRAVEL TOO SMALL (ACTIVE) ........................374 REAR FAN POT OPEN (ACTIVE) .........................................375 REAR FAN POT SHORTED (ACTIVE) .....................................375 REAR MODE POT OPEN (ACTIVE) .......................................375 REAR MODE POT SHORTED (ACTIVE) ...................................375 REAR KEYBOARD FAULT (ACTIVE) ......................................376 REAR MODE DOOR NOT RESPONDING (ACTIVE) ..........................380 REAR MODE DOOR TRAVEL TOO LARGE (ACTIVE) ........................382 REAR MODE DOOR TRAVEL TOO SMALL (ACTIVE) .........................383 RECIRC DOOR NOT RESPONDING (ACTIVE) ..............................384 RECIRC DOOR TRAVEL TOO LARGE (ACTIVE).............................386 RECIRC DOOR TRAVEL TOO SMALL (ACTIVE) .............................387 *ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE .........................388 *FRONT BLOWER MOTOR INOPERATIVE .................................390 *FRONT BLOWER RUNS AT ONLY ONE SPEED ............................396 *HVAC SYSTEM TEST ..................................................398 *REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE .................402 *REAR BLOWER MOTOR INOPERATIVE ..................................404 *REAR BLOWER RUNS AT ONLY ONE SPEED .............................410 CABIN HEATER A. CABIN HEATER PRE-TEST ...........................................412 CABIN HEATER CONTROL CIRCUIT OPEN (STORED) .......................412 CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (STORED) ..........412 B1000 CONTROL UNIT ERRONEOUS .....................................416 B1800 NO START ......................................................417 B1801 FLAME OUT: DURING HEATING CYCLE .............................417 B1801 FLAME OUT: UNSTABLE OPERATION ...............................417 B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD........421 viii

TABLE OF CONTENTS - Continued B1802 POWER SUPPLY OUT OF RANGE: VOLTAGEABOVE 15.5 VOLTS .......424 B1803 FLAME DETECTED PRIOR TO COMBUSTION ........................425 B1811 HEATER OVERHEATED ...........................................426 B1813 HEATER IN LOCKOUT MODE ......................................430 B1820 DOSING PUMP CIRCUIT: OPEN OR SHORT TO BATTERY .............433 B1820 DOSING PUMP CIRCUIT: SHORT TO GROUND .......................436 B1821 COMBUSTION AIR FAN CIRCUIT: OPEN .............................439 B1821 COMBUSTION AIR FAN CIRCUIT: SHORT TO GROUND ................439 B1822 GLOW PIN/FLAME SENSOR: OPEN ................................440 B1822 GLOW PIN/FLAME SENSOR: SHORT TO GROUND ...................440 B1823 WATER PUMP CIRCUIT: OPEN.....................................441 B1823 WATER PUMP CIRCUIT: SHORTTO GROUND........................441 B1824 FAN SWITCH LINE SHORT TO GROUND ............................442 CABIN HEATER CONTROL CIRCUIT OPEN (ACTIVE) ........................443 CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE)...........447 *CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE (MTC) .........450 *CABIN HEATER INOPERABLE FROM AUTO TEMP CONTROL (ATC) ..........452 CHIME *CHIME INOPERATIVE..................................................455 *KEY IN IGNITION AND DRIVER’S DOOR OPEN CHIME NOT OPERATING PROPERLY ...........................................................457 *PROBLEM WITH THE VEHICLE SPEED WARNING CHIME...................458 COMMUNICATION APM MESSAGES NOT RECEIVED ........................................459 ATC MODULE MESSAGES NOT RECEIVED ................................460 AUDIO MESSAGES NOT RECEIVED ......................................461 BCM, PCI BUS SHORTED TO BATTERY ...................................462 BCM, PCI BUS SHORTED TO GROUND ...................................462 FCM, PCI BUS SHORTED TO BATTERY ...................................462 FCM, PCI BUS SHORTED TO GROUND ...................................462 COUNTRY CODE NOT PROGRAMMED ...................................464 FCM MESSAGES NOT RECEIVED ........................................465 FCM, BCM COMMUNICATION FAULT .....................................466 FCM, HVAC COMMUNICATION FAULT ....................................467 FCM, PCI INTERNAL FAULT .............................................468 FCM, PCM COMMUNICATION FAULT .....................................469 FCM, RADIO COMMUNICATION FAULT ...................................471 FCM, TCM COMMUNICATION FAULT .....................................472 INTERNAL BCM FAILURE ...............................................473 LEFT PSD MESSAGES NOT RECEIVED ...................................474 LIFTGATE MODULE MESSAGES NOT RECEIVED...........................476 MIC MESSAGES NOT RECEIVED ........................................478 MSM MESSAGES NOT RECEIVED .......................................480 ORC MESSAGES NOT RECEIVED........................................481 OTIS MODULE MESSAGE MISMATCH ....................................482 OTIS MODULE MESSAGES NOT RECEIVED ...............................484 PCI INTERNAL HARDWARE FAILURE .....................................485 PCM MESSAGES NOT RECEIVED........................................486 RADIO MEM MSG NOT RECEIVED .......................................488 RIGHT PSD MESSAGES NOT RECEIVED..................................489 SKIM (SKREEM) MESSAGES NOT RECEIVED..............................491 ix

TABLE OF CONTENTS - Continued TCM MESSAGES NOT RECEIVED ........................................492 *NO RESPONSE FROM AMPLIFIER ......................................493 *NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL MODULE .....495 *NO RESPONSE FROM BODY CONTROL MODULE .........................497 *NO RESPONSE FROM CABIN HEATER ASSIST - DIESEL ONLY ..............499 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE ...................501 *NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY .....................503 *NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY ....................504 *NO RESPONSE FROM FRONT CONTROL MODULE ........................506 *NO RESPONSE FROM HANDS FREE MODULE ............................508 *NO RESPONSE FROM HVAC ...........................................510 *NO RESPONSE FROM INSTRUMENT CLUSTER ...........................512 *NO RESPONSE FROM LEFT SLIDING DOOR CONTROL MODULE............515 *NO RESPONSE FROM MEMORY SEAT/MIRROR/ADJUSTABLE PEDALS MODULE .............................................................518 *NO RESPONSE FROM OCCUPANT CLASSIFICATION MODULE ..............520 *NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER ..............522 *NO RESPONSE FROM OVERHEAD CONSOLE ............................524 *NO RESPONSE FROM PARK ASSIST MODULE ............................526 *NO RESPONSE FROM PCM (PCI BUS) - NGC .............................528 *NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC .......................529 *NO RESPONSE FROM POWER LIFTGATE MODULE .......................532 *NO RESPONSE FROM RADIO ..........................................535 *NO RESPONSE FROM RIGHT SLIDING DOOR CONTROL MODULE ..........537 *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE .............540 *NO RESPONSE FROM THATCHAM ALARM MODULE .......................542 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE - EATX (DIESEL) .544 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE - NGC ..........547 *PCI BUS COMMUNICATION FAILURE ....................................550 DOOR AJAR *HOOD AJAR CIRCUIT OPEN (EXPORT ONLY) .............................553 *HOOD AJAR CIRCUIT SHORTED TO GROUND (EXPORT ONLY) .............554 *LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN .................555 *LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND. .556 *LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN ................557 *LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND .............................................................559 *LIFTGATE AJAR CIRCUIT OPEN.........................................560 *LIFTGATE AJAR CIRCUIT SHORTED TO GROUND .........................561 *RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN ................562 *RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND .............................................................563 *RIGHT SLIDING DOOR AJAR CIRCUIT OPEN .............................564 *RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND ..............566 ELECTRICALLY HEATED SYSTEMS EBL RUN ONLY RELAY OPEN ...........................................567 EBLRUN ONLY RELAY SHORTED TO BATTERY............................569 x

2004 Chrysler Grand Voyager Service & Repair Manual

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