jump start CHRYSLER VOYAGER 2001 User Guide

Inspection and service should also be performed
anytime a malfunction is observed or suspected.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on any
suspension component, including the front suspen-
sion crossmember, the rear leaf springs, and the
rear axle. Do not hoist on the front and rear
bumpers, the lower liftgate crossmember, the lower
radiator crossmember, the down standing flanges
on the sill or the front engine mount.
FOR PROPER HOIST PLACEMENT REFER
TO (Fig. 8).
The hoisting points are identified by S.A.E.
inverted triangle hoisting symbols (Fig. 8). The front
hoisting points are at the bottom of the font rail
below the hoisting symbol approximately 250mm
behind the front suspension crossmember. When
using outboard lift hoists, verify that the hoist lift
pads have been properly adjusted to eliminate con-
tact between the hoist arm and the down standing
flange on the sill. The rear hoisting points are the
leaf spring front mounting brackets. The hoist pad
must be positioned to pick up the flanges on the
bracket, not the leaf spring.
When servicing the leaf springs or the leaf spring
mounting brackets, special provisions are required to
support the rear of the vehicle. Position the rear
hoist pads under the horizontal surface on the bot-
tom of the sill, inboard adjacent to the flange and
centered fore/aft between the jacking indicator tabs
on the lower flange.DO NOT HOIST ON THE
FLANGE.Place a soft pad between the hoist and the
painted surface on the sill to avoid scratching the fin-
ish.
JUMP STARTING
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
Fig. 8 HOISTING AND JACKING POINTS
1 - DRIVE ON LIFT
2 - FRAME CONTACT LIFT (SINGLE POST)
CHASSIS LIFT (NON-AXLE DUAL POST)
OUTBOARD LIFT (DUAL POST)
FLOOR JACK
3 - S.A.E. HOISTING SYMBOLS
0 - 16 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 9).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 minutes), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
²FWD vehicles, use a flat bed towing device or
wheel lift is recommended (Fig. 10).
²AWD vehicles, a flat bed towing device or wheel
lift and towing dolly is recommended (Fig. 10).
When using a wheel lift towing device, be sure the
disabled vehicle has at least 100 mm (4 in.) ground
clearance. If minimum ground clearance cannot be
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15
degrees.
Fig. 9 Jumper Cable Clamp Connections
1 - BATTERY POSITIVE CABLE
2 - POSITIVE JUMPER CABLE
3 - TEST INDICATOR
4 - BATTERY NEGATIVE CABLE
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
7 - ENGINE GROUND
RSLUBRICATION & MAINTENANCE0-17
JUMP STARTING (Continued)

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO
DIESEL
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE - RG - 2.5 L
TURBO DIESEL
SPECIFICATIONS.........................1
INTERNATIONAL SYMBOLS
DESCRIPTION............................2
FLUID TYPES
DESCRIPTION............................2
FLUID FILL/CHECK LOCATIONS
DESCRIPTION............................5
MAINTENANCE SCHEDULES
DESCRIPTION............................5HOISTING
STANDARD PROCEDURE...................7
HOISTING.............................7
JUMP STARTING
STANDARD PROCEDURE...................8
JUMP STARTING........................8
TOWING
STANDARD PROCEDURE...................8
TOWING RECOMMENDATIONS.............8
LUBRICATION &
MAINTENANCE - RG - 2.5 L
TURBO DIESEL
SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3 L 4.0 L (4.5 qts.)
Engine Oil* - 2.5 L 5.22 L (5.52 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 3.3 L
without Auxiliary Heater12.6 L (13.4 qts.)
Cooling System** - 3.3 L
with Auxiliary Heater15.4 L (16.3 qts.)
Cooling System** - 2.5 L
Turbo Diesel without
Auxiliary Heater13.8 L (14.6 qts.)
DESCRIPTION SPECIFICATION
Cooling System** - 2.5 L
Turbo Diesel with
Auxiliary Heater16.6 L (17.5 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
31TH Overhaul Fill8.6 L (9.1 qts.)
Automatic Transaxle -
41TE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-speed)2.4-2.7 L (2.5-2.9 qts.)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch0.575 L (1.22 pts.)
AWD Rear Carrier 0.7 L (1.48 pts.)
*(includes oil filter)
**(includes heater and recovery/reserve bottle)
RGLUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL0a-1

JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3)
On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accessories.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 8).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 minutes), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
Fig. 8 Jumper Cable Clamp Connections
1 - BATTERY POSITIVE CABLE
2 - POSITIVE JUMPER CABLE
3 - TEST INDICATOR
4 - BATTERY NEGATIVE CABLE
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
7 - ENGINE GROUND
0a - 8 LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESELRG

BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery system is standard factory-
installed equipment on this model. All of the compo-
nents of the battery system are located within the
engine compartment of the vehicle. The service infor-
mation for the battery system in this vehicle covers
the following related components, which are covered
in further detail elsewhere in this service manual:
²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Thermoguard- The battery thermo-
guard insulates the battery to protect it from engine
compartment temperature extremes.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to Lubrication
and Maintanance for the recommended battery main-
tenance schedules and for the proper battery jump
starting procedures. While battery charging can be
considered a maintenance procedure, the battery
charging procedures and related information are
located in the standard procedures section of this ser-
vice manual. This was done because the battery must
be fully-charged before any battery system diagnosis
or testing procedures can be performed. Refer to
Standard procedures for the proper battery charging
procedures.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a single complete system. In order for the engine
to start and the battery to charge properly, all of the
components that are used in these systems must per-
form within specifications. It is important that the
battery, starting, and charging systems be thoroughly
tested and inspected any time a battery needs to be
charged or replaced. The cause of abnormal battery
discharge, overcharging or early battery failure must
be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
8F - 2 BATTERY SYSTEMRS

²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to the Battery section
for more information.
²Ignition Switch- Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
²Transmission Range Sensor- Visually inspect
the transmission range sensor for indications of phys-
ical damage and loose or corroded wire harness con-
nections.
²Starter Relay- Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.²Starter- Visually inspect the starter for indica-
tions of physical damage and loose or corroded wire
harness connections.
²Starter Solenoid- Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
²Wiring- Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required. Check for loose or corroded wire harness
connections at main engine ground and remote jump
post.
²Power Distribution Center (PDC)- Visually
inspect the B+ connections at the PDC for physical
damage and loose or corroded harness connections.
STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS
TO ENGAGE.1. BATTERY
DISCHARGED OR
FAULTY.1. REFER TO THE BATTERYSECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY, IF
REQUIRED.
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY
FAULTY.3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. IGNITION SWITCH
FAULTY.4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. PARK/NEUTRAL
POSITION SWITCH
(AUTO TRANS) FAULTY
OR MIS-ADJUSTED.5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
SWITCH, IF NECESSARY.
6. CLUTCH PEDAL
POSITION SWITCH
(MAN TRANS) FAULTY.6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
7. STARTER SOLENOID
FAULTY.7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
8. STARTER ASSEMBLY
FAULTY.8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
9. FAULTY TEETH ON
RING GEAR.9. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.1. BATTERY
DISCHARGED OR
FAULTY.1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY AS
NECESSARY.
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
8F - 28 STARTINGRS
STARTING (Continued)

(5) Connect a remote starter switch or a jumper
wire between the remote battery positive post and
terminal 87 of the starter relay connector.
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Particularly at starter terminals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK/NEUTRAL POSITION
WITH THE PARKING BRAKE APPLIED.
RELAY TEST
The starter relay is located in the Power Distribu-
tion Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.
Remove the starter relay from the PDC as
described in this group to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 7565 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery B+ lead to terminals 86 and
a ground lead to terminal 85 to energize the relay.
The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity
between terminals 87A and 30. If OK, refer to Relay
Circuit Test procedure. If not OK, replace the faulty
relay.
CAV FUNCTION
30 B (+)
85 P/N POSITION SW.SENSE
(AUTO)
86 IGNITION SWITCH
OUTPUT
87 STARTER RELAY OUTPUT
RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position.
Check for battery voltage at the cavity for relay ter-
minal 86 with the ignition switch in the Start posi-
tion, and no voltage when the ignition switch is
released to the On position. If OK, go to Step 5. If
not OK, check for an open or short circuit to the igni-
tion switch and repair, if required. If the circuit to
the ignition switch is OK, see the Ignition Switch
Test procedure in this group.
Starter Relay Pinout
Starter Relay Pinout
8F - 30 STARTINGRS
STARTING (Continued)

8W-10 POWER DISTRIBUTION
Component PageA/C Compressor Clutch..................8Wa-10-19, 20, 38, 40
A/C Compressor Clutch Relay.............8Wa-10-19, 20, 37, 38, 40
Accessory Relay.......................8Wa-10-15, 26, 57
Ambient Temp Sensor........................8Wa-10-54
Auto Shut Down Relay......................8Wa-10-19, 34
Auto Temp Control.........................8Wa-10-33
Back-Up Lamp Switch........................8Wa-10-58
Battery........................8Wa-10-12, 13, 14, 34, 40
Blower Motor Resistor......................8Wa-10-17, 31
Body Control Module......8Wa-10-21, 33, 38, 41, 42, 44, 46, 47, 48, 49, 61
Brake Fluid Level Switch......................8Wa-10-57
Brake Lamp Switch.....................8Wa-10-21, 44, 59
Brake Transmission Shift Interlock Solenoid.............8Wa-10-55
Cabin Heater Assist.....................8Wa-10-20, 36, 52
Camshaft Position Sensor......................8Wa-10-37
Center High Mounted Stop Lamp..................8Wa-10-59
Clockspring.............................8Wa-10-53
Clutch Pedal Interlock Switch Jumper........8Wa-10-16, 30, 46, 47, 53
Clutch Pedal Interlock Switch............8Wa-10-16, 30, 46, 47, 53
Controller Antilock Brake...........8Wa-10-16, 21, 30, 42, 48, 54, 59
Crank Case Ventilation Heater...................8Wa-10-41
Data Link Connector.......................8Wa-10-29, 61
Defogger Relay......................8Wa-10-17, 18, 32, 56
Diagnostic Junction Port.......................8Wa-10-54
Driver Door Lock Switch.....................8Wa-10-28, 29
Driver Heated Seat Module.....................8Wa-10-42
Driver Power Seat Switch......................8Wa-10-42
Driver Power Window Switch....................8Wa-10-29
ECM/PCM Relay.........................8Wa-10-20, 36
EGR Solenoid..........................8Wa-10-37, 39
Electric Wiper De-Icer........................8Wa-10-28
Engine Control Module........8Wa-10-16, 20, 30, 36, 37, 40, 41, 58, 59
Floor Console Lamp.........................8Wa-10-27
Floor Console Power Outlet...................8Wa-10-27, 29
Front Blower Module......................8Wa-10-17, 31
Front Blower Motor Relay................8Wa-10-16, 17, 31, 56
Front Cigar Lighter.......................8Wa-10-15, 27
Front Control Module . . . 8Wa-10-14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25,
26, 29, 30, 31, 32, 38, 40, 45, 46, 47, 50, 51, 52, 53, 54. 55, 56, 57, 58, 59, 61
Front Fog Lamp Relay....................8Wa-10-14, 22, 56
Front Washer Pump Motor..................8Wa-10-15, 26, 61
Front Wiper Hi/Low Relay..................8Wa-10-15, 25, 57
Front Wiper On/Off Relay..................8Wa-10-15, 25, 52
Fuel Heater.............................8Wa-10-41
Fuel Heater Relay......................8Wa-10-20, 40, 57
Fuel Injector No. 1..........................8Wa-10-35
Fuel Injector No. 2..........................8Wa-10-35
Fuel Injector No. 3..........................8Wa-10-35
Fuel Injector No. 4..........................8Wa-10-35
Fuel Injector No. 5..........................8Wa-10-35
Fuel Injector No. 6..........................8Wa-10-35
Fuel Pressure Solenoid.......................8Wa-10-37
Fuel Pump Module........................8Wa-10-19, 38
Fuel Pump Relay.......................8Wa-10-19, 38, 57
Fuse 1 (IPM).........................8Wa-10-14, 15, 22
Fuse 2 (IPM) (Diesel).....................8Wa-10-14, 10-24
Fuse 2 (IPM) (Gas)......................8Wa-10-14, 10-23
Fuse 3 (IPM).........................8Wa-10-14, 23, 24
Fuse 4 (IPM).......................8Wa-10-14, 15, 16, 25
Fuse 5 (IPM)...........................8Wa-10-15, 26
Fuse 6 (IPM)...........................8Wa-10-15, 26
Fuse 8 (IPM)...........................8Wa-10-16, 29
Fuse 9 (IPM).........................8Wa-10-16, 17, 30
Fuse 10 (IPM)..........................8Wa-10-17, 31
Fuse 11 (IPM)..........................8Wa-10-15, 26
Fuse 12 (IPM)..........................8Wa-10-17, 31
Fuse 13 (IPM)..........................8Wa-10-18, 32
Fuse 14 (IPM)....................8Wa-10-18, 19, 20, 32, 52
Fuse 15 (IPM) (Diesel)......................8Wa-10-20, 36
Fuse 15 (IPM) (Gas).....................8Wa-10-18, 19, 34
Fuse 16 (IPM) (Diesel)......................8Wa-10-20, 36
Fuse 16 (IPM) (Gas).......................8Wa-10-19, 34
Fuse 17 (IPM) (Diesel)......................8Wa-10-20, 40
Fuse 17 (IPM) (Gas).......................8Wa-10-19, 38
Fuse 18 (IPM)....................8Wa-10-19, 20, 21, 38, 40
Fuse 19 (IPM)......................8Wa-10-19, 20, 21, 42
Fuse 20 (IPM)..........................8Wa-10-21, 42
Fuse 21 (IPM)..........................8Wa-10-21, 42
Fuse 22 (IPM)..........................8Wa-10-21, 42
Fuse 23 (IPM)........................8Wa-10-21, 46, 47
Fuse 24 (IPM)............................8Wa-10-21
Fuse 24 (IPM)............................8Wa-10-44
Fuse 26 (IPM)..........................8Wa-10-21, 44
Fuse 27 (IPM)..........................8Wa-10-21, 44
Fuse 28 (IPM)..........................8Wa-10-15, 26
Fuse 30 (IPM)..........................8Wa-10-21, 45
Fuse 31 (IPM)..........................8Wa-10-21, 45
Fuse 32 (IPM)..........................8Wa-10-21, 45
Fuse 33 (IPM)............................8Wa-10-15
Fuse 33 (IPM)............................8Wa-10-26
Fuselink.............................8Wa-10-12, 13
G100................................8Wa-10-48
G101...............................8Wa-10-34, 40
G103................................8Wa-10-61
G300................................8Wa-10-50
G300................................8Wa-10-51
Generator........................8Wa-10-12, 13, 35, 37
Glow Plug Relay.........................8Wa-10-12, 37
Headlamp Switch........................8Wa-10-24, 55Component PageHeadlamp Washer Pump Motor.................8Wa-10-21, 45
Headlamp Washer Relay...................8Wa-10-21, 45, 56
High Note Horn...........................8Wa-10-29
Horn Relay..........................8Wa-10-16, 29, 52
Ignition Coil.............................8Wa-10-35
Ignition Switch............8Wa-10-16, 21, 30, 38, 39, 41, 46, 47, 53
Instrument Cluster.......................8Wa-10-21, 44
Intelligent Power Module . . 8Wa-10-2, 10-3, 10-4, 10-12, 14, 15, 16, 17, 18, 19,
20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40,
41, 42, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 61
Leak Detection Pump........................8Wa-10-39
Left B-Pillar Switch.........................8Wa-10-28
Left Combination Relay.......................8Wa-10-60
Left Fog Lamp..........................8Wa-10-14, 22
Left Front Park/ Turn Signal Lamp............8Wa-10-14, 23, 49, 58
Left Headlamp............................8Wa-10-50
Left Headlamp Leveling Motor................8Wa-10-24, 55, 58
Left High Beam Lamp........................8Wa-10-51
Left Low Beam Lamp........................8Wa-10-51
Left Park Lamp.........................8Wa-10-24, 58
Left Power Mirror..........................8Wa-10-32
Left Rear Lamp Assembly..............8Wa-10-23, 24, 58, 59, 60
Left Repeater Lamp.........................8Wa-10-44
Left Side Impact Airbag Control Module...............8Wa-10-55
Left Sliding Door Control Module..................8Wa-10-45
Left Stop/ Turn Signal Relay.....................8Wa-10-60
Left Turn Signal Lamp.......................8Wa-10-49
License Lamp........................8Wa-10-23, 24, 58
Lift Pump Motor.........................8Wa-10-20, 36
Lift Pump Relay.........................8Wa-10-20, 36
Low Note Horn...........................8Wa-10-29
Mass Air Flow Sensor........................8Wa-10-37
Memory Seat/ Mirror Module....................8Wa-10-42
Message Center...........................8Wa-10-44
Name Brand Speaker Relay.................8Wa-10-18, 32, 52
Occupant Restraint Controller..................8Wa-10-56, 61
Overhead Console..........................8Wa-10-33
Oxygen Sensor 1/1 Upstream....................8Wa-10-35
Oxygen Sensor 1/2 Downstream...................8Wa-10-35
Park Lamp Relay.....................8Wa-10-14, 23, 24, 52
Park/ Neutral Position Switch....................8Wa-10-58
Passenger Door Lock Switch...................8Wa-10-26, 28
Passenger Folding Mirror Relay.............8Wa-10-19, 20, 38, 40
Passenger Heated Seat Module...................8Wa-10-43
Passenger Power Seat Switch....................8Wa-10-43
Passenger Power Window Switch..................8Wa-10-26
Power Liftgate Module......................8Wa-10-21, 45
Power Mirror Switch...................8Wa-10-19, 20, 39, 40
Power Outlet............................8Wa-10-29
Power Seat Circuit Breaker...................8Wa-10-21, 42
Power Window Circuit Breaker.................8Wa-10-15, 26
Powertrain Control Module........8Wa-10-16, 19, 30, 34, 35, 38, 39, 48
PTC4 ..............................8Wa-10-18, 32
Ptc7.............................8Wa-10-15, 16, 29
Radiator Fan Relay.....................8Wa-10-21, 44, 48
Radiator Fan Relay No. 1....................8Wa-10-12, 37
Radiator Fan Relay No. 2....................8Wa-10-37, 44
Radiator Fan Relay No. 3....................8Wa-10-21, 37
Radio..............................8Wa-10-27, 33
Radio Choke...........................8Wa-10-18, 32
Rear A/C-Heater Unit......................8Wa-10-17, 31
Rear Blower Motor Power Module..................8Wa-10-31
Rear Blower Motor Relay.................8Wa-10-17, 18, 31, 56
Rear Power Outlet......................8Wa-10-15, 26, 27
Rear Washer Pump Motor..................8Wa-10-15, 26, 61
Rear Window Defogger Grid...................8Wa-10-18, 32
Rear Wiper Motor..........................8Wa-10-28
Remote Keyless Entry Module....................8Wa-10-33
Right B-Pillar Switch........................8Wa-10-28
Right Combination Relay......................8Wa-10-60
Right Fog Lamp.........................8Wa-10-14, 22
Right Front Park/ Turn Signal Lamp...........8Wa-10-14, 23, 49, 53
Right Headlamp...........................8Wa-10-50
Right Headlamp Leveling Motor...............8Wa-10-24, 53, 55
Right High Beam Lamp.......................8Wa-10-51
Right Low Beam Lamp.......................8Wa-10-51
Right Park Lamp........................8Wa-10-24, 53
Right Power Mirror.........................8Wa-10-32
Right Rear Lamp Assembly................8Wa-10-14, 23, 24, 59
Right Repeater Lamp........................8Wa-10-44
Right Side Impact Airbag Control Module..............8Wa-10-55
Right Sliding Door Control Module.................8Wa-10-45
Right Stop/ Turn Signal Relay....................8Wa-10-60
Right Turn Signal Lamp.......................8Wa-10-49
Sentry Key Immobilizer Module...........8Wa-10-33, 39, 41, 46, 47
Solenoid/ Pressure Switch Assy...................8Wa-10-34
Starter Motor.......................8Wa-10-12, 13, 16, 30
Starter Motor Relay...................8Wa-10-16, 30, 46, 47
Thatcham Alarm Module.................8Wa-10-39, 41, 47, 61
Torque Converter Clutch Solenoid..................8Wa-10-39
Trailer Tow Connector......................8Wa-10-23, 58
Transmission Control Module...........8Wa-10-16, 19, 30, 34, 54, 55
Transmission Control Relay...................8Wa-10-19, 34
Transmission Range Sensor.....................8Wa-10-58
TXV Solenoid............................8Wa-10-31
Vehicle Speed Sensor........................8Wa-10-36
Washer Fluid Level Switch.....................8Wa-10-53
Wiper Module........................8Wa-10-15, 25, 52
RG8W-10 POWER DISTRIBUTION8Wa-10-1

8W-21 STARTING SYSTEM
Component Page
Battery......................... 8Wa-21-2, 3
Clutch Pedal Interlock Switch
Jumper....................... 8Wa-21-2, 3
Clutch Pedal Interlock Switch........ 8Wa-21-2, 3
Engine Control Module............... 8Wa-21-3
Front Control Module................ 8Wa-21-2
Fuse 9 (IPM)..................... 8Wa-21-2, 3
Fuselink........................ 8Wa-21-2, 3Component Page
G101........................... 8Wa-21-2, 3
Generator....................... 8Wa-21-2, 3
Ignition Switch................... 8Wa-21-2, 3
Intelligent Power Module........... 8Wa-21-2, 3
Powertrain Control Module............ 8Wa-21-2
Starter Motor.................... 8Wa-21-2, 3
Starter Motor Relay............... 8Wa-21-2, 3
RG8W-21 STARTING SYSTEM8Wa-21-1

When testing voltage or continuity at any control
module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the
insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second DTC could be set, making diagnosis of the
original problem more difficult.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBIIIt(diagnostic read-out box) scan tool
Evaporative System Diagnostic Kit #6917
fuel filler adapter #8382
fuel pressure adapter (C-6631) or #6539
fuel pressure kit (C-4799-B) or #5069
fuel release hose (C-4799-1)
Min Air flow fitting #6714
jumper wires
ohmmeter
oscilloscope
vacuum gauge
voltmeter
12 volt test light minimum 25 ohms resistance
with probe #6801
CAUTION: A 12 VOLT TEST LIGHT SHOULD
NOT BE USED FOR THE FOLLOWING
CIRCUITS, DAMAGE TO THE POWERTRAIN
CONTROLLER WILL OCCUR.
²5 Volt Supply
²8 Volt Supply
²J1850 PCI Bus
²CCD Bus
²CKP Sensor Signal
²CMP Sensor Signal
²Vehicle Speed Sensor Signal
²O2 Sensor Signal
6.0 GLOSSARY OF TERMS
ABSanti-lock brake system
backfire,
popbackfuel ignites in either the intake or
the exhaust system
CKPcrank position sensor
CMPcamshaft position sensorcuts out,
missesa steady pulsation or the inability of
the engine to maintain a consistent
rpm
DLCdata link connector (previously
called engine diagnostic connector)
detona-
tion,
spark
knocka mild to severe ping, especially un-
der loaded engine conditions
ECTengine coolant temperature sensor
EGRexhaust gas recirculation valve
genera-
torpreviously called alternator
hard
startThe engine takes longer than usual
to start, even though it is able to
crank normally.
hesita-
tion, sag,
stumbleThere is a momentary lack of re-
sponse when the throttle is opened.
This can occur at all vehicle speeds.
If it is severe enough, the engine
may stall.
IATintake air temperature sensor
IACidle air control motor
JTECCombined engine and transmission
control module
lack of
power,
sluggishThe engine has less than expected
power, with little or no increase in
vehicle speed when the throttle is
opened.
LDPleak detection pump
MAPmanifold absolute pressure sensor
MILmalfunction indicator lamp
MTVmanifold tuning valve
O2Soxygen sensor
PCIprogrammable communication inter-
face
PCMpowertrain control module
PCVpositive crankcase ventilation
PEPperipheral expansion port
poor fuel
economyThere is significantly less fuel mile-
age than other vehicles of the same
design ad configuration
12
GENERAL INFORMATION