tow CHRYSLER VOYAGER 1996 Owners Manual

Component Page
Seat Belt Switch.....................8W-80-83
Sentry Key Immobilizer Module.........8W-80-83
Speed Control Dimming Module.........8W-80-83
Stop Lamp Switch....................8W-80-83
Throttle Position Sensor (2.0L)..........8W-80-84
Throttle Position Sensor (Except 2.0L). . . .8W-80-84
Traction Control Switch................8W-80-84
Trailer Tow Connector.................8W-80-84
Transmission Control Module...........8W-80-85Component Page
Transmission Control Solenoids..........8W-80-86
Transmission Range Sensor.............8W-80-86
Turbine Speed Sensor.................8W-80-87
Turbo Boost Pressure Sensor............8W-80-87
Upstream Heated Oxygen Sensor........8W-80-87
Vehicle Speed Control Servo............8W-80-87
Vehicle Speed Sensor..................8W-80-88
Wiper Module (Built-Up-Export).........8W-80-88
Wiper Module (Except Built-Up-Export) . . .8W-80-88
8W - 80 - 4 8W - 80 CONNECTOR PIN-OUTSNS/GS

Z1 20BK
L50 18WT/TN 3
61
4
BLACKBLACK
4 1
6 3
L63 18DG/RD
6 5 1Z1 18BK Z1 20BK L50 18WT/TN
L50 18WT/TN L77 20BR/LB L1 20VT/BK L63 18DG/RD L63 18DG/RD
4 3 2 CAV
- CIRCUIT
6 5 1
L77 20BR/LB L1 20VT/BK
4 3
2 CAV
- CIRCUIT
3
61
4
BLACKBLACK
4 1
6 3
Z1 20BK L78 20DG/YL L62 18BR/RD
6 4 1Z1 18WT Z1 20BK L50 18WT/TN L78 18BR
L78 20DG/YL L1 20VT/BK L62 18BR/RD L62 18BR/RD
5 3 2 CAV
- CIRCUIT
6 4 1
L50 18WT/TN L1 20VT/BK
5 3 2 CAV
- CIRCUIT
B99
(TRAILER TOW) (TRAILER TOW)B98 T08
T05
DOOR ACTUATORBLEND
2 1
BACK-UP
SWITCH
BACK-UP LAMP FEED L1 18VT/BK
2F20 20WT* FUSED IGNITION SWITCH OUTPUTFUSED IGNITION SWITCH OUTPUT F20 18WT
1 1
CAV FUNCTION CIRCUIT
* DIESEL FUNCTION
CIRCUIT
BLEND AIR DOOR DRIVER
5 VOLT SUPPLY
BLEND DOOR FEEDBACK SIGNAL
SENSOR GROUND
BLEND AIR DOOR DRIVERCAV
1
2
3
4
5C33 20DB/RD
C26 20PK/DB
C36 20RD/WT
C57 20DB/GY
C34 20DB/WTNATURAL
1 5
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8014

LAMP KEY-IN HALO
WHITE
1 2
1
M11 20PK/LB Z1 20BK
2 CAV COURTESY LAMP SWITCH OUTPUT GROUND CIRCUIT
FUNCTION
(PREMIUM)SPEAKER LEFT DOOR
LEFT INSTRUMENT PANEL SPEAKER (-)
X55 20BR/RD LEFT FRONT SPEAKER (-)RADIO CHOKE OUTPUT X13 16RD/DG
6
5
3 6
4
1 BLACK
X156 20VT/WT* X53 20DG X15 16BK/DG X154 20WT/VT*
4 3 2 1 CAV
LEFT FRONT SPEAKER (+) AMPLIFIED SPEAKER GROUND LEFT INSTRUMENT PANEL SPEAKER (+)FUNCTION CIRCUIT
RELAY LEFT COMBINATION
4
2
3 5 1BLACK
GROUND
3 2
L615 18OR L50 18WT/TN
L50 18WT/TN Z1 18BK Z1 18BK
L63 18DG/RD
5 4 1 CAV LEFT COMBINATION RELAY OUTPUT
STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT LEFT TURN SIGNAL
- CIRCUIT
- FUNCTION
(2.0L/2.4L/3.8L) KNOCK SENSOR
21
GRAY
K4 18BK/LB K42 18DB/LG
2 1 CAV SENSOR GROUND KNOCK SENSOR SIGNAL CIRCUIT
FUNCTION
SWITCHKEY-IN
1 2GREEN
Z1 20BK G26 20LB
2 1 CAV GROUND KEY-IN IGNITION SWITCH SENSE CIRCUIT
FUNCTION
(TRAILER TOW)
X153 20WT/BR** LEFT INSTRUMENT PANEL SPEAKER (+)
X155 20BR/WT**
LEFT INSTRUMENT PANEL SPEAKER (-)
** LHD* RHD
8W - 80 - 48 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8048

MIRROR LAMPS LEFT VISOR/VANITY
ABBLACK
F41 20PK/VT M20 20BR
B A CAV FUSED B (+) COURTESY LAMP GROUND FUNCTION CIRCUIT
SIGNAL RELAY LEFT STOP/TURN
1 4
2
3 5
BLACK
LEFT COMBINATION RELAY OUTPUT LEFT STOP/TURN SIGNAL OUTPUT 1
4 2L615 18OR L63 18DG/RD L63 18DG/RD L73 18YL
Z1 18BK Z1 18BK
L50 18WT/TN L50 18WT/TN
5 3 CAV
LEFT REAR TURN SIGNAL GROUND STOP LAMP SWITCH OUTPUT CIRCUIT
FUNCTION
GRAY
GROUND Z1 18BK
2
1L63 18DG/RD CAV FUNCTION CIRCUIT
LEFT REPEATER LAMP SIGNAL
1 2
SENSOR WHEEL SPEEDLEFT REAR
GRAY
21
B4 18LG B3 18LG/DB
2 1 CAV LEFT REAR WHEEL SPEED SENSOR (+) LEFT REAR WHEEL SPEED SENSOR (-) FUNCTION CIRCUIT
LEFT REAR VENT MOTOR (OPEN) Q24 18DG
3
31NATURAL
LEFT REAR
VENT MOTOR
(RHD)
LEFT REAR VENT MOTOR (CLOSE) Q14 18GY
2
1- CAV FUNCTION CIRCUIT
-
LEFT REPEATER
LAMP
(BUILT-UP-EXPORT)
(TRAILER TOW)
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53
NSGS8053J988W-3

RELAY RIGHT COMBINATION- -
BLACK4
2
3 5
RIGHT TURN SIGNAL
1
L605 18DG L50 18WT/TN Z1 18BK L62 18BR/RD
L62 18BR/RD
5 4 3 2 CAV RIGHT TURN SIGNAL STOP LAMP SWITCH OUTPUT GROUND CIRCUIT
FUNCTION
(EXCEPT BUILT-UP-EXPORT)FOG LAMPRIGHT
FOG LAMP RELAY OUTPUT L39 18LB**
GRAY*
1 PURPLE**
2
Z39 20BK L39 18VT/RD*
2 1 CAV FOG LAMP SWITCHED GROUND FOG LAMP RELAY OUTPUT CIRCUIT
FUNCTION BLACK
FOG LAMP SWITCHED GROUND Z39 20BK
2
1F39 18PK/LG CAV FUNCTION CIRCUIT
FUSED PARK LAMP RELAY OUTPUT
RIGHT
FOG LAMP
(BUILT-UP-EXPORT)
1 2
(PREMIUM)SPEAKER RIGHT DOOR
X56 20DB/RD RIGHT FRONT SPEAKER (-)RADIO CHOKE OUTPUT X13 16RD/DG
65
3 6
4
1 BLACK
X155 20BR/WT X54 20VT X15 16BK/DG X153 20WT/BR
4 3 2 1 CAV RIGHT FRONT I/P SPEAKER (-) RIGHT FRONT SPEAKER (+) AMPLIFIED SPEAKER GROUND RIGHT I/P SPEAKER (+)FUNCTION CIRCUIT
PANEL SPEAKERRIGHT FRONT3
4X153 20WT/BR-
RIGHT FRONT I/P SPEAKER (+)-
BLACK
4
1
- X155 20BR/WT
2 1 CAV - RIGHT FRONT I/P SPEAKER (-) CIRCUIT
FUNCTION
(TRAILER TOW)
(PREMIUM)
RHD
LHD
DIESEL
* DODGE/PLYMOUTH
** CHRYSLER X154 20WT/VT RIGHT FRONT I/P SPEAKER (+)
X156 20VT/WT
RIGHT FRONT I/P SPEAKER (-)
GRAY
X156 20VT/WT RIGHT FRONT I/P SPEAKER (-)
X154 20WT/VT RIGHT I/P SPEAKER (+)
8W - 80 - 78 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8078

SWITCH STOP LAMP
1
6 GRAY
F32 18PK/DB L50 18WT/TN
V30 20DB/RD* V32 20YL/RD* Z1 20BK
K29 20WT/PK
6 5 4
3 2 1 CAV FUSED B(+)
STOP LAMP SWITCH OUTPUT SPEED CONTROL BRAKE SWITCH OUTPUT SPEED CONTROL ON/OFF SWITCH SENSE
GROUND STOP LAMP SWITCH SENSE FUNCTION CIRCUIT
* GAS
DIMMING MODULESPEED CONTROL
4BLACK1
V32 20YL/RD V38 20LB/RD L97 29PK/DB
4 3 2 1 CAV SPEED CONTROL ON/OFF SWITCH SENSE
SPEED CONTROL RELAY CONTROL PARK LAMP RELAY CONTROL
- FUNCTION
- CIRCUIT
BLACK
(BUILT-UP-EXPORT)
6 1
MODULE IMMOBILIZERSENTRY KEY
CAV CIRCUIT FUNCTION
1 F41 20PK/VT FUSED B(+)
2 Z2 20BK GROUND
3 F87 20WT/BK FUSED IGNITION (ST-RUN)
4- -
5 D2 20WT/BK CCD BUS (-)
6 D1 20VT/BR CCD BUS (+)
SWITCH SEAT BELT
2 1BLACK
Z1 20BK G10 18LG/RD
2 1 CAV GROUND SEAT BELT SWITCH SENSE FUNCTION CIRCUIT
VANITY MIRROR LAMPSRIGHT VISOR/
ABBLACK
F41 20PK/VT M20 20BR
B A CAV FUSED B(+) COURTESY LAMP GROUND FUNCTION CIRCUIT
SIGNAL RELAYSTOP/TURNRIGHT
BLACK4
2
3 5
2 1
GROUND STOP LAMP SWITCH OUTPUT
L605 18DG L62 18BR/RD L74 18LG Z1 18BK
Z1 18BK L50 18WT/TN L50 18WT/TN
5 4
3 CAV RIGHT COMBINATION RELAY OUTPUT RIGHT TURN SIGNAL STOP LAMP SWITCH OUTPUTFUNCTION CIRCUIT
(TRAILER TOW)
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83
NSGS8083J988W-3

CONNECTOR TRAILER TOW
CAP
L73 18YL Z1 18WT
L78 18BR
L74 18LG
4 3 2 1 CAV STOP LAMP SWITCH OUTPUT
GROUND
FUSED B(+) STOP LAMP SWITCH OUTPUT CIRCUIT
FUNCTION
SWITCH TRACTION CONTROL
E2 20OR B27 20RD/YL Z1 20BK
3 2
1 CAV PANEL LAMP FEED
TRACTION CONTROL SWITCH SENSE GROUND CIRCUIT
FUNCTION
3 1BLACK
(EXCEPT 2.0L) POSITION SENSORTHROTTLE
K4 18BK/LB
SENSOR GROUND 1
3
CAV CIRCUIT FUNCTION
1
K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL 2
K6 18VT/WT 5 VOLT SUPPLY
3
CIRCUIT FUNCTION
CAV
1
2K4 18BK/LB CRANK POSITION SENSOR
THROTTLE POSITION SENSOR SIGNAL K22 18OR/DB
3K6 18VT/WT 5V SUPPLY
(2.0L) SENSOR THROTTLE POSITION
WHITE
31
WHITE
8W - 80 - 84 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8084

Component/
GroundColor Location Fig.
Right Door
Arm/Disarm
SwitchBK At Switch 17
Right Door
Courtesy LampBK At Lamp 17
Right Door
SpeakerBK At Speaker 17
Right Flasher
RelayBK LT Quarter
PanelN/S
Right Front Fog
LampBK At Lamp 4
Right Front
Door Ajar
SwitchBK RT B-Pillar 12
Right Front
Door Lock
MotorBK At Motor 17
Right Front
Panel SpeakerBK At Speaker 11
Right Front
Park/Turn
Signal LampBK At Lamp 4
Right Front
Wheel Speed
SensorBK Right Fender
Side Shield4
Right Front
Window MotorRD At Motor 19
Right Headlamp BK At Lamp 4
Right Headlamp
Leveling MotorBK At Motor N/S
Right Liftgate
Flood LampBK At Lamp 23
Right Mid
Reading LampGY At Lamp 17
Right Power
Door Lock
SwitchBK At Switch 19
Right Power
Mirror C1RD At Mirror 11
Right Power
Mirror C2BL At Mirror 11
Right Power
Window SwitchBK At Switch 19
Right Rear
Lamp AssemblyBK At Lamp 22
Right Rear Door
Ajar SwitchBK RT C-Pillar 22Component/
GroundColor Location Fig.
Right Rear Pillar
SpeakerBK At Speaker 22
Right Rear
Reading LampGY At Lamp 17
Right Rear
Sliding Door
ContactBK RT B-Pillar 14
Right Rear
Sliding Door
Lock MotorBK At Motor N/S
Right Rear
SpeakerBK At Speaker 22
Right Rear Vent
MotorNAT At Motor 22
Right Rear
Wheel Speed
SensorBK Center Rear of
Floor Pan16
Right Repeater
LampGY At Lamp N/S
Right Speed
Control SwitchRight Side of
Steering Wheel
Pad11
Right Stop/Turn
Signal RelayBK LT Quarter
PanelN/S
Right Visor/
Vanity LampBK At Lamp 17
S02 BK Under Seat N/S
Seat Belt Switch BK LT B-Pillar N/S
Sentry Key
Immobilizer
ModuleBK Near Steering
at Module11
Stop Lamp
SwitchGY Top of Brake
Pedal13
T05 BK LT Quarter
PanelN/S
T08 BK LT Quarter
PanelN/S
Throttle Position
SensorNAT On Throttle
Body5, 6, 7,
8, 9
Trailer Tow
ConnectorBK LT Quarter
PanelN/S
Transmission
Control ModuleBK RT Fender Side
Shield3
Transmission
Range SensorBK Top of
Transmission7, 9
8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

Component/
GroundColor Location Fig.
Right Rear
Sliding Door
ContactBK RT B-Pillar 14
Right Rear
Sliding Door
Lock MotorBK At Motor N/S
Right Rear
SpeakerBK At Speaker 22
Right Rear Vent
MotorNAT At Motor 22
Right Rear
Wheel Speed
SensorGY Center Rear of
Floor Pan16
Right Repeater
LampGY At Lamp N/S
Right Speed
Control SwitchRight Side of
Steering Wheel
Pad11
Right Stop/Turn
Signal RelayBK LT Quarter
PanelN/S
Right Visor/
Vanity LampBK At Lamp 17
S02 BK Under Seat N/S
Seat Belt Switch BK RT B-Pillar N/S
Sentry Key
Immobilizer
ModuleBK Near Steering
Column at
Module11
Stop Lamp
SwitchGY Top of Brake
Pedal12
T05 BK LT Quarter
PanelN/S
T08 BK RT Quarter
PanelN/SComponent/
GroundColor Location Fig.
Throttle Position
SensorNAT On Throttle
Body5, 6, 7,
8, 9
Trailer Tow
ConnectorBK LT Quarter
PanelN/S
Transmission
Control ModuleBK RT Fender Side
Shield3
Transmission
Range SensorBK Top of
Transmission7. 9
Transmission
Control
SolenoidsBK Front of
Transmission7, 9
Turbine Speed
SensorGY Front of
Transmission7, 9
Turn Signal/
Hazard SwitchBK Part of
Multifunction
Switch11
Upstream
Heated Oxygen
SensorGY Rear of Engine 5, 6, 7,
8, 9
Vehicle Speed
Control ServoBK LT Rear of
Engine
Compartment5, 6, 7,
8, 9
Vehicle Speed
SensorBK Rear of
Transmission5, 6, 8
Windshield
Wiper SwitchBK Part of
Multifunction
Switch11
Wiper Module BK LT Side of
Engine2
8W - 90 - 36 8W - 90 CONNECTOR/GROUND LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces to
remove all loose material. Inspect stamped parts to
ensure gasket rails are flat. Gasket surfaces must be
free of oil and dirt. Make sure old gasket material is
removed from blind attaching holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing the material off location.
TheMopartSilicone Rubber Adhesive Sealant
gasket material or equivalent should be applied in a
continuous bead approximately 3 mm (0.120 in.) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop
is placed in the center of the gasket contact area.
Uncured sealant may be removed with a shop towels.
Components should be torqued in place while the
sealant is still wet to the touch (within 10 minutes).
The usage of a locating dowel is recommended during
assembly to prevent smearing of material off loca-
tion.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 1). With the cup plug rotated, grasp firmlywith pliers or other suitable tool and remove plug
(Fig. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with sealer. Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is at
least 0.5 mm (0.020 inch.) inside the lead in chamfer
(Fig. 1).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-
ing to these standards, refer to Engine Diagnosis out-
lined is this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis, outlined in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINENS
GENERAL INFORMATION (Continued)