electric CHRYSLER VOYAGER 2002 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2002Pages: 2399, PDF Size: 57.96 MB
Page 678 of 2399
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch....... 8W-10-22, 24, 45, 47
A/C Compressor Clutch
Relay................ 8W-10-22, 24, 44, 45, 47
Accessory Relay................ 8W-10-16, 31, 64
Adjustable Pedals Module........... 8W-10-40, 46
Airbag Control Module............. 8W-10-63, 68
Ambient Temp Sensor................. 8W-10-61
Auto Shut Down Relay............. 8W-10-21, 41
Auto Temp Control................... 8W-10-40
Back-Up Lamp Switch................ 8W-10-65
Battery................. 8W-10-13, 14, 15, 41, 47
Blower Motor Resistor.............. 8W-10-19, 38
Body Control Module...... 8W-10-25, 40, 45, 48, 49,
51, 53, 54, 55, 56, 68
Brake Fluid Level Switch.............. 8W-10-64
Brake Lamp Switch............. 8W-10-26, 51, 66
Brake Transmission Shift Interlock
Solenoid......................... 8W-10-62
Cabin Heater Assist............. 8W-10-23, 43, 59
Camshaft Position Sensor.............. 8W-10-44
Center High Mounted Stop Lamp........ 8W-10-66
Clockspring........................ 8W-10-60
Clutch Pedal Interlock
Switch............... 8W-10-18, 37, 53, 54, 60
Clutch Pedal Interlock Switch
Jumper............... 8W-10-18, 37, 53, 54, 60
Controller Antilock
Brake.......... 8W-10-18, 25, 37, 49, 55, 61, 66
Crank Case Ventilation Heater.......... 8W-10-48
Data Link Connector............... 8W-10-36, 68
Defogger Relay.............. 8W-10-19, 20, 39, 63
Diagnostic Junction Port............... 8W-10-61
Driver Door Lock Switch............ 8W-10-33, 35
Driver Heated Seat Module............. 8W-10-49
Driver Power Seat Switch.............. 8W-10-49
Driver Power Window Switch........ 8W-10-34, 35
ECM/PCM Relay.................. 8W-10-23, 43
EGR Solenoid.................... 8W-10-44, 46
Electric Wiper De-Icer................. 8W-10-33
Engine Control Module . . 8W-10-18, 23, 24, 37, 43, 44,
47, 48, 65, 66
Floor Console Lamp.................. 8W-10-32
Floor Console Power Outlet.......... 8W-10-32, 36
Front Blower Module............... 8W-10-19, 38
Front Blower Motor Relay..... 8W-10-18, 19, 38, 63
Front Cigar Lighter................ 8W-10-16, 32
Front Control Module..... 8W-10-15, 16, 17, 18, 19,
20, 22, 24, 26, 27, 28, 29,
30, 31, 36, 37, 38, 39, 45,
47, 52, 53, 54, 57, 58, 59,
60, 61, 62, 63, 64, 65, 66, 68
Front Fog Lamp Relay........... 8W-10-15, 27, 63
Component Page
Front Washer Pump Motor........ 8W-10-16, 31, 68
Front Wiper Hi/Low Relay........ 8W-10-16, 30, 64
Front Wiper On/Off Relay........ 8W-10-16, 30, 59
Fuel Heater........................ 8W-10-48
Fuel Heater Relay.............. 8W-10-24, 47, 64
Fuel Injector No. 1................... 8W-10-42
Fuel Injector No. 2................... 8W-10-42
Fuel Injector No. 3................... 8W-10-42
Fuel Injector No. 4................... 8W-10-42
Fuel Injector No. 5................... 8W-10-42
Fuel Injector No. 6................... 8W-10-42
Fuel Pressure Solenoid................ 8W-10-44
Fuel Pump Module................ 8W-10-22, 45
Fuel Pump Relay............... 8W-10-22, 45, 64
Fuse 1....................... 8W-10-15, 16, 27
Fuse 2....................... 8W-10-15, 28, 29
Fuse 3....................... 8W-10-15, 28, 29
Fuse 4.................... 8W-10-15, 16, 17, 30
Fuse 5.......................... 8W-10-16, 31
Fuse 6.......................... 8W-10-16, 31
Fuse 8.......................... 8W-10-17, 36
Fuse 9.................... 8W-10-17, 18, 19, 37
Fuse 10......................... 8W-10-19, 38
Fuse 11......................... 8W-10-16, 31
Fuse 12......................... 8W-10-19, 38
Fuse 13......................... 8W-10-20, 39
Fuse 14................ 8W-10-20, 21, 23, 39, 59
Fuse 15........... 8W-10-20, 21, 22, 23, 24, 41, 43
Fuse 16................... 8W-10-21, 23, 41, 43
Fuse 17.............. 8W-10-21, 22, 23, 24, 45, 47
Fuse 18................ 8W-10-22, 24, 25, 45, 47
Fuse 19................ 8W-10-22, 24, 25, 26, 49
Fuse 20......................... 8W-10-25, 49
Fuse 21......................... 8W-10-25, 49
Fuse 22......................... 8W-10-25, 49
Fuse 23...................... 8W-10-25, 53, 54
Fuse 24......................... 8W-10-25, 51
Fuse 26...................... 8W-10-25, 26, 51
Fuse 27......................... 8W-10-26, 51
Fuse 28......................... 8W-10-16, 31
Fuse 30......................... 8W-10-26, 52
Fuse 31......................... 8W-10-26, 52
Fuse 32......................... 8W-10-26, 52
Fuse 33......................... 8W-10-16, 31
Fuselink........................ 8W-10-13, 14
G100............................. 8W-10-55
G101........................... 8W-10-41, 47
G103............................. 8W-10-68
G300........................... 8W-10-57, 58
Generator................. 8W-10-13, 14, 42, 44
Glow Plug Relay.................. 8W-10-13, 44
Headlamp Switch................. 8W-10-29, 62
RS8W-10 POWER DISTRIBUTION8W-10-1
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Page 868 of 2399
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Clutch............ 8W-42-14, 16
A/C Compressor Clutch Relay....... 8W-42-14, 16
A/C Pressure Sensor.............. 8W-42-14, 16
A/C- Heater Control.......... 8W-42-2, 3, 4, 5, 7
ATC Remote Sensor................. 8W-42-11
Auto Temp Control...... 8W-42-8, 9, 10, 11, 12, 13
Battery........................... 8W-42-17
Blower Motor Resistor................ 8W-42-2
Body Control Module........... 8W-42-4, 7, 9, 13
Diagnostic Junction Port............. 8W-42-4, 9
Driver Blend Door Actuator......... 8W-42-5, 10
ECM/PCM Relay.................... 8W-42-17
Electric Wiper De-Icer............... 8W-42-3, 8
Engine Control Module............ 8W-42-16, 17
Evaporator Temperature Sensor...... 8W-42-5, 10
Front Blower Module................ 8W-42-11
Front Blower Motor................ 8W-42-2, 11
Front Blower Motor Relay........... 8W-42-2, 11
Front Control Module......... 8W-42-2, 6, 11, 12
Fuse 10......................... 8W-42-2, 11
Fuse 12......................... 8W-42-6, 12
Fuse 14............................ 8W-42-8
Fuse 16........................... 8W-42-17
Fuse 18........................ 8W-42-14, 16
Fuse 27........................ 8W-42-15, 18
Fuselink.......................... 8W-42-17
G102.......................... 8W-42-15, 18Component Page
G103.......................... 8W-42-14, 16
G200.............. 8W-42-2, 3, 4, 6, 8, 9, 11, 12
G300........................... 8W-42-7, 13
G302............................. 8W-42-12
Integrated Power
Module . . 8W-42-2, 6, 8, 11, 12, 14, 15, 16, 17, 18
Mode Door Actuator............... 8W-42-5, 10
Passenger Blend Door Actuator....... 8W-42-5, 10
Powertrain Control Module......... 8W-42-14, 15
Radiator Fan No. 1............ 8W-42-15, 17, 18
Radiator Fan No. 2............... 8W-42-15, 18
Radiator Fan Relay.................. 8W-42-15
Radiator Fan Relay No. 1.......... 8W-42-17, 18
Radiator Fan Relay No. 2............. 8W-42-18
Radiator Fan Relay No. 3............. 8W-42-18
Rear A/C-Heater Unit............... 8W-42-6, 7
Rear Auto Temp Control Switch........ 8W-42-13
Rear Blower Front Control Switch....... 8W-42-6
Rear Blower Motor.................. 8W-42-12
Rear Blower Motor Power Module...... 8W-42-12
Rear Blower Motor Relay........... 8W-42-6, 12
Rear Blower Rear Control Switch...... 8W-42-6, 7
Rear Mode Motor................... 8W-42-12
Rear Temperature Motor.............. 8W-42-12
Recirculation Door Actuator......... 8W-42-5, 10
TXV Solenoid...................... 8W-42-12
RS8W-42 AIR CONDITIONING-HEATER8W-42-1
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Page 936 of 2399
8W-48 REAR WINDOW DEFOGGER
Component Page
A/C- Heater Control.................. 8W-48-2
Accessory Relay..................... 8W-48-2
Auto Temp Control................... 8W-48-2
Defogger Relay...................... 8W-48-2
Electric Wiper De-Icer................. 8W-48-2
Front Control Module................. 8W-48-2
Fuse 11............................ 8W-48-2
Fuse 13............................ 8W-48-2Component Page
G200.............................. 8W-48-3
G400.............................. 8W-48-2
Integrated Power Module.............. 8W-48-2
Left Power Mirror.................... 8W-48-3
PTC4 ............................. 8W-48-2
Rear Window Defogger Grid............ 8W-48-2
Right Power Mirror................... 8W-48-3
RS8W-48 REAR WINDOW DEFOGGER8W-48-1
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Page 1033 of 2399
Component Page
C322 (Memory)..................... 8W-80-39
C322 (Memory)..................... 8W-80-39
C324 (Manual Sliding Door)........... 8W-80-39
C324 (Manual Sliding Door)........... 8W-80-40
C325 (Manual Sliding Door)........... 8W-80-40
C325 (Manual Sliding Door)........... 8W-80-40
C326............................. 8W-80-40
C326............................. 8W-80-40
C327............................. 8W-80-40
C327............................. 8W-80-41
C329 (Diesel)....................... 8W-80-41
C329 (Diesel)....................... 8W-80-41
C330 (Diesel)....................... 8W-80-41
C330 (Diesel)....................... 8W-80-41
C331 (Diesel)....................... 8W-80-42
C331 (Diesel)....................... 8W-80-42
C332 (ATC)........................ 8W-80-42
C332 (ATC)........................ 8W-80-42
Cabin Heater Assist C1 (Diesel)........ 8W-80-42
Cabin Heater Assist C2 (Diesel)........ 8W-80-43
Camshaft Position Sensor (Diesel)...... 8W-80-43
Camshaft Position Sensor (Gas)........ 8W-80-43
CD Changer....................... 8W-80-43
Center Dome Lamp (Base/High Line).... 8W-80-43
Center High Mounted Stop Lamp....... 8W-80-44
Clockspring C1..................... 8W-80-44
Clockspring C2..................... 8W-80-44
Clockspring C3..................... 8W-80-44
Clockspring C4..................... 8W-80-44
Clockspring C5..................... 8W-80-45
Clutch Pedal Interlock Switch (MTX).... 8W-80-45
Clutch Pedal Interlock Switch Jumper
(ATX) .......................... 8W-80-45
Clutch Pedal Upstop Switch (Diesel)..... 8W-80-45
Controller Antilock Brake............. 8W-80-46
Crank Case Ventilation Heater (Diesel) . . 8W-80-46
Crankshaft Position Sensor (Diesel)..... 8W-80-46
Crankshaft Position Sensor (Gas)....... 8W-80-47
Data Link Connector................. 8W-80-47
Diagnostic Junction Port.............. 8W-80-47
Dosing Pump (Diesel)................ 8W-80-48
Driver Airbag C1.................... 8W-80-48
Driver Airbag C2.................... 8W-80-48
Driver Blend Door Actuator (ATC)...... 8W-80-48
Driver Blend Door Actuator (MTC)...... 8W-80-48
Driver Door Courtesy Lamp........... 8W-80-49
Driver Door Lock Switch.............. 8W-80-49
Driver Heated Seat Back............. 8W-80-49
Driver Heated Seat Cushion........... 8W-80-49
Driver Heated Seat Module C1......... 8W-80-49
Driver Heated Seat Module C2......... 8W-80-50
Driver Heated Seat Module C3......... 8W-80-50
Driver Power Seat Front Riser Motor.... 8W-80-50Component Page
Driver Power Seat Front Riser
Position Sensor................... 8W-80-50
Driver Power Seat Horizontal Motor..... 8W-80-50
Driver Power Seat Horizontal
Position Sensor................... 8W-80-51
Driver Power Seat Rear Riser Motor.... 8W-80-51
Driver Power Seat Rear Riser
Position Sensor................... 8W-80-51
Driver Power Seat Recliner Motor...... 8W-80-51
Driver Power Seat Recliner
Position Sensor................... 8W-80-51
Driver Power Seat Switch............. 8W-80-52
Driver Power Window Motor........... 8W-80-52
Driver Power Window Switch
(Except Lowline).................. 8W-80-52
Driver Power Window Switch (Lowline) . . 8W-80-53
Driver Power Window Switch (RHD).... 8W-80-53
Driver Seat Belt Switch.............. 8W-80-53
Driver Seat Belt Tensioner............ 8W-80-53
EGR Solenoid (Diesel)................ 8W-80-54
EGR Solenoid (Gas)................. 8W-80-54
Electric Wiper De-Icer C1............. 8W-80-54
Electric Wiper De-Icer C2............. 8W-80-54
Engine Control Module C1 (Diesel)...... 8W-80-55
Engine Control Module C2 (Diesel)...... 8W-80-57
Engine Coolant Temp Sensor (Diesel).... 8W-80-57
Engine Coolant Temp Sensor (Gas)...... 8W-80-58
Engine Oil Pressure Sensor (Diesel)..... 8W-80-58
Engine Oil Pressure Switch (Gas)....... 8W-80-58
Engine Oil Temperature Sensor (Diesel) . . 8W-80-58
EVAP/Purge Solenoid (Gas)............ 8W-80-58
Evaporator Temperature Sensor........ 8W-80-59
Floor Console Lamp................. 8W-80-59
Floor Console Power Outlet........... 8W-80-59
Front Blower Module C1 (ATC)......... 8W-80-59
Front Blower Module C2 (ATC)......... 8W-80-59
Front Cigar Lighter................. 8W-80-60
Front Reading Lamps/Switch.......... 8W-80-60
Front Washer Pump Motor............ 8W-80-60
Fuel Heater (Diesel)................. 8W-80-60
Fuel Injector No. 1 (2.4L/3.3L/3.8L)..... 8W-80-60
Fuel Injector No. 1 (Diesel)............ 8W-80-61
Fuel Injector No. 2 (2.4L/3.3L/3.8L)..... 8W-80-61
Fuel Injector No. 2 (Diesel)............ 8W-80-61
Fuel Injector No. 3 (2.4L/3.3L/3.8L)..... 8W-80-61
Fuel Injector No. 3 (Diesel)............ 8W-80-61
Fuel Injector No. 4 (2.4L/3.3L/3.8L)..... 8W-80-62
Fuel Injector No. 4 (Diesel)............ 8W-80-62
Fuel Injector No. 5 (3.3L/3.8L)......... 8W-80-62
Fuel Injector No. 6 (3.3L/3.8L)......... 8W-80-62
Fuel Pressure Sensor (Diesel).......... 8W-80-62
Fuel Pressure Solenoid (Diesel)......... 8W-80-63
Fuel Pump Module.................. 8W-80-63
Generator......................... 8W-80-63
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTSRS
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Page 1085 of 2399
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K35 20GY/YL EGR SOLENOID CONTROL
2 K342 16BR/WT ECM/PCM RELAY OUTPUT
EGR SOLENOID (GAS) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K35 18DB/VT EGR SOLENOID CONTROL
2 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
ELECTRIC WIPER DE-ICER C1 - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
2- -
ELECTRIC WIPER DE-ICER C2 - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 C900 18LB/VT WIPER DE-ICER DRIVER
2- -
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTSRS
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Page 1151 of 2399
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Driver Power Seat Front Riser
MotorRD At Seat N/S
Driver Power Seat Horizontal Motor BK At Seat N/S
Driver Power Seat Rear Riser
MotorRD At Seat N/S
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor N/S
Driver Power Window Switch GN At Switch N/S
Driver Power Window Switch
(RHD)NAT At Switch N/S
Driver Seatbelt Switch WT At Switch on Seat Harness N/S
Driver Seatbelt Tensioner On Seat Harness N/S
EGR Solenoid (Diesel) BK Above Transmission
Right Side of EngineN/S
EGR Solenoid GY Above Transmission
Right Side of Engine9, 10, 11, 13
Electric Wiper De-Icer-C1 WT Right Side Instrument Panel 15, 1923
Electric Wiper De-Icer-C2 WT Left Side Instrument Panel 15, 16, 22
Engine Control Module C1 (Diesel) BK Right Side of Engine 11
Engine Control Module C2 (Diesel) BK Right Side of Engine 11
Engine Coolant Temperature
Sensor (Gas)BK On Cylinder Block N/S
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 11
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 12
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 9
Engine Oil Temperature Sensor
(Diesel)BK Rear of Engine 12
EVAP/Purge Solenoid BK Right Motor Mount 9, 13
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 15, 18, 20
Front Reading Lamps/Switch BK At Switch N/S
Front Washer Pump Motor BK Right Fender Well 3
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 11
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 11
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1196 of 2399
8W-97 POWER DISTRIBUTION SYSTEM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
ACCESSORY RELAY
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY
RELAY...............................2
REMOVAL.............................3
INSTALLATION..........................3
INTEGRATED POWER MODULE
DESCRIPTION..........................3OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4
IOD FUSE
DESCRIPTION..........................4
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................5
POWER OUTLET
DESCRIPTION..........................5
OPERATION............................5
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 5
REMOVAL.............................6
INSTALLATION..........................6
POWER DISTRIBUTION
SYSTEM
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Outlets
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses
²Circuit splice blocks
²Flashers
²Fusible links
²Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1
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Page 1197 of 2399
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
ACCESSORY RELAY
DESCRIPTION
The accessory relay is an electromechanical device
that switches fused battery current to the accessory
powered vehicle circuits when the ignition switch is
turned to the Accessory or On positions. The delay
feature will maintain power to the accessories for 45
seconds after the ignition is shut off or until a door is
opened. This allows sufficient time to close windows
and park the windshield wipers. The accessory relay
is located in the Integrated Power Module (IPM) in
the engine compartment.
The accessory relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
The accessory relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one movable)
electrical contacts. The movable (common feed) relay
contact is held against one of the fixed contacts (normal-
ly closed) by spring pressure. When the electromagnetic
coil is energized, it draws the movable contact away
from the normally closed fixed contact, and holds it
against the other (normally open) fixed contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY RELAY
The accessory relay (Fig. 1) is located in the Inte-
grated Power Module (IPM), in the engine compart-
ment. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Remove the accessory relay from the IPM.
Refer toAccessory Relayin the Removal and
Installation section of this group for the procedure.
(2) 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 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75 5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the IPM is connected to battery voltage and should
be hot at all times. Check for battery voltage at the
fused B(+) circuit cavity in the IPM receptacle for the
accessory relay. If OK, go to Step 2. If not OK, repair
the fused B(+) circuit to the IPM 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 fused B(+) fuse in the IPM that feeds the
accessories when the relay is energized by the igni-
tion switch. There should be continuity between the
IPM cavity for relay terminal 87 and the fused B(+)
fuse in the IPM at all times. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the IPM
fuse as required.
Terminal Pick Kit 6680
Fig. 1 Accessory Relay
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER DISTRIBUTION SYSTEM (Continued)
ProCarManuals.com
Page 1199 of 2399
tion of the service manual for complete IPM circuit
schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard from the
vehicle. Refer to the Battery section for the proce-
dure.
(3) Remove the battery from the vehicle. Refer to
the Battery section for the procedure.
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 3).
(5) Rotate the IPM counter-clockwise to access and
disconnect the various electrical connectors (Fig. 4).
(6) Free the IPM from its mounting bracket by
removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.
INSTALLATION
(1) Snap the left side of the Integrated Power Mod-
ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors. Care must be
taken that the Connector Positive Assurance (CPA)
on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).
NOTE: IPM electrical connectors are color coded to
ease location reference.(2) Being certain no wires are stressed or pinched,
rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.
(3) Install the battery in the vehicle. Refer to the
Battery section for the procedure.
(4) Install the battery thermal guard in the vehi-
cle. Refer to the Battery section for the procedure.
(5)
Connect the negative and positive battery cables.
(6) Using a diagnostic scan tool, check for any
stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) when
the vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.
The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
Fig. 3 RELEASING INTEGRATED POWER MODULE
FROM ITS MOUNTING BRACKET
Fig. 4 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS
INTEGRATED POWER MODULE (Continued)
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Page 1200 of 2399
tion. The IOD fuse is a 15 ampere blade-type car-
tridge fuse and, when removed, it is stored in a fuse
cavity adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.
(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Remove the stored 15 amp IOD fuse from fuse
storage markedSPAREof the IPM.
(4) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(5) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
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