automatic transmission CHRYSLER VOYAGER 2002 Owner's Guide
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2002Pages: 2399, PDF Size: 57.96 MB
Page 676 of 2399
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch Relay............ 8W-42
A/C Compressor Clutch................. 8W-42
A/C- Heater Control.................... 8W-42
A/C Pressure Sensor................... 8W-42
A/C-Heater Control.................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Accessory Relay....................... 8W-10
Adjustable Pedals Module............... 8W-30
Adjustable Pedals Switch................ 8W-30
Airbag Control Module.................. 8W-43
Ambient Temp Sensor.................. 8W-49
Antenna............................. 8W-47
Auto Shut Down Relay................. 8W-30
Auto Temp Control..................... 8W-42
Automatic Day/Night Mirror............. 8W-49
Back-Up Lamp Switch.................. 8W-51
Battery Temperature Sensor............. 8W-20
Battery............................. 8W-20
Blend Door Actuators................... 8W-42
Body Control Module................... 8W-45
Boost Pressure Sensor.................. 8W-30
B-Pillar Switches...................... 8W-61
Brake Lamp Switch................. 8W-30, 51
Brake Transmission Shift Interlock
Solenoid........................... 8W-31
Cabin Heater Assist.................... 8W-30
Camshaft Position Sensor............... 8W-30
CD Changer.......................... 8W-47
Center High Mounted Stop Lamp......... 8W-51
Cinch/Release Motors................... 8W-61
Clockspring.................. 8W-33, 41, 43, 47
Clutch Pedal Interlock Switch Jumper..... 8W-10
Clutch Pedal Interlock Switch............ 8W-10
Combination Relays.................... 8W-54
Controller Antilock Brake............... 8W-35
Crank Case Ventilation Heater........... 8W-30
Crankshaft Position Sensor.............. 8W-30
Cylinder Lock Switches................. 8W-39
Data Link Connector................... 8W-18
Diagnostic Junction Port................ 8W-18
Door Ajar Switches.................... 8W-39
Door Lock Motor/Ajar Switches........... 8W-61
Door Lock Switches.................... 8W-61
Driver Airbag......................... 8W-43
EGR Solenoid......................... 8W-30
Electric Wiper De-Icer.................. 8W-48
Engine Control Module................. 8W-30
Engine Coolant Temp Sensor............. 8W-30
Engine Oil Pressure Switch.............. 8W-30
EVAP/Purge Solenoid................... 8W-30
Evaporator Temperature Sensor.......... 8W-42
Floor Console Lamp.................... 8W-44Component Page
Fog Lamps........................... 8W-50
Front Blower Module................... 8W-42
Front Blower Motor Relay............... 8W-42
Front Blower Motor.................... 8W-42
Front Cigar Lighter.................... 8W-41
Front Control Module.................. 8W-10
Front Fog Lamp Relay.................. 8W-50
Front Intrusion Sensor................. 8W-39
Front Washer Pump Motor.............. 8W-53
Front Wiper On/Off Relay............... 8W-53
Fuel Heater.......................... 8W-30
Fuel Injectors........................ 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Pump Module.................... 8W-30
Full Open Switches.................... 8W-61
Fuselink............................. 8W-10
Fuses............................... 8W-10
Generator............................ 8W-20
Glow Plug Relay...................... 8W-30
Glow Plugs........................... 8W-30
Grounds............................. 8W-15
Halo Lamp........................... 8W-44
Headlamp Leveling Motors.............. 8W-50
Headlamp Switch...................... 8W-50
Headlamp Washer Relay................ 8W-53
Headlamps........................... 8W-50
Heated Seat Backs..................... 8W-63
Heated Seat Cushions.................. 8W-63
Heated Seat Modules................... 8W-63
High Beam Lamps..................... 8W-50
High Note Horn....................... 8W-41
Horn Relay.......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coil.......................... 8W-30
Ignition Switch....................... 8W-10
Inlet Air Temperature Sensor............ 8W-30
Instrument Cluster.................... 8W-40
Instrument Panel Switch Bank . . 8W-44, 52, 53, 63
Integrated Power Module................ 8W-10
Knock Sensor......................... 8W-30
License Lamp......................... 8W-51
Lift Pump Motor...................... 8W-30
Liftgate Ajar Switch................. 8W-39, 61
Liftgate Cinch/Release Motor............. 8W-61
Liftgate Cylinder Lock Switch............ 8W-39
Liftgate Flood Lamps................... 8W-44
Liftgate Right Pinch Sensor.............. 8W-61
Low Beam Lamps.................... 8W-50-9
Manifold Absolute Pressure Sensor........ 8W-30
Mass Air Flow Sensor.................. 8W-30
Memory Seat/Mirror Module.......... 8W-62, 63
Memory Set Switch.................... 8W-63
RS8W-02 COMPONENT INDEX8W-02-1
ProCarManuals.com
Page 746 of 2399
8W-15 GROUND DISTRIBUTION
Component PageA/C Compressor Clutch...................8W-15-7, 8
A/C- Heater Control....................8W-15-9, 11
Adjustable Pedals Module..................8W-15-17
Airbag Control Module....................8W-15-12
Auto Temp Control.......................8W-15-9
Automatic Day/Night Mirror.................8W-15-21
Autostick Switch........................8W-15-10
Back-Up Lamp Switch....................8W-15-3, 7
Battery.............................8W-15-2, 3
Body Control Module.....................8W-15-22
Brake Fluid Level Switch...................8W-15-17
Brake Lamp Switch......................8W-15-17
Cabin Heater Assist.......................8W-15-8
Center Dome Lamp......................8W-15-21
Center High Mounted Stop Lamp..............8W-15-26
Clutch Pedal Upstop Switch.................8W-15-18
Controller Antilock Brake..................8W-15-2, 3
Crank Case Ventilation Heater................8W-15-8
Crankshaft Position Sensor..................8W-15-3
Data Link Connector..................8W-15-2, 3, 17
Dosing Pump...........................8W-15-8
Driver Door Courtesy Lamp...............8W-15-15, 20
Driver Door Lock Switch.................8W-15-15, 20
Driver Heated Seat Cushion.................8W-15-11
Driver Heated Seat Module.................8W-15-11
Driver Power Seat Switch..................8W-15-11
Driver Power Window Switch..............8W-15-15, 20
Engine Control Module.....................8W-15-3
Floor Console Lamp......................8W-15-25
Floor Console Power Outlet.................8W-15-25
Front Blower Module.....................8W-15-11
Front Cigar Lighter.......................8W-15-9
Front Control Module..................8W-15-7, 8, 18
Front Reading Lamps/Switch................8W-15-21
Fuel Heater...........................8W-15-25
Fuel Heater Relay........................8W-15-3
Fuel Pump Module.......................8W-15-25
G100..............................8W-15-2, 3
G101..............................8W-15-2, 3
G102.............................8W-15-4, 5, 6
G103..............................8W-15-7, 8
G200...........................8W-15-9, 10, 11
G201...............................8W-15-12
G202...............................8W-15-13
G300........................8W-15-14, 16, 17, 18
G301........................8W-15-19, 20, 21, 22
G302...........................8W-15-23, 24, 25
G400.............................8W-15-25, 26
Glove Box Lamp........................8W-15-10
Halo Lamp............................8W-15-10
Headlamp Switch........................8W-15-9
Headlamp Washer Pump Motor................8W-15-6
High Note Horn........................8W-15-5, 6
Hood Ajar Switch........................8W-15-18
Instrument Cluster.......................8W-15-9
Instrument Panel Switch Bank...............8W-15-10
Integrated Power Module............8W-15-2, 3, 7, 8, 18
Left B-Pillar Switch......................8W-15-17
Left Cinch/Release Motor...................8W-15-14
Left Combination Relay....................8W-15-24
Left Cylinder Lock Switch................8W-15-15, 16
Left Door Speaker.......................8W-15-13
Left Fog Lamp........................8W-15-5, 6
Left Front Door Ajar Switch.................8W-15-16
Left Front Door Lock Motor/Ajar Switch.......8W-15-15, 16
Left Front Park/Turn Signal Lamp..............8W-15-5
Left Full Open Switch.....................8W-15-14
Left Headlamp.........................8W-15-18
Left Headlamp Leveling Motor................8W-15-6
Left High Beam Lamp....................8W-15-18
Left Liftgate Flood Lamp...................8W-15-26
Left Low Beam Lamp.....................8W-15-18
Left Mid Reading Lamp....................8W-15-21
Left Park Lamp.........................8W-15-18
Left Power Mirror.......................8W-15-10
Left Rear Lamp Assembly..................8W-15-24
Left Rear Reading Lamp...................8W-15-21
Left Side Impact Airbag Control Module.........8W-15-12
Left Sliding Door Control Module..............8W-15-14
Left Sliding Door Latch Sensing Switch..........8W-15-14
Left Sliding Door Lock Motor................8W-15-14Component PageLeft Sliding Door Lock Motor/Ajar Switch.........8W-15-14
Left Sliding Door Motor....................8W-15-14
Left Stop/Turn Signal Relay.................8W-15-24
Left Turn Signal Lamp....................8W-15-18
Left Visor/Vanity Lamp....................8W-15-21
License Lamp........................8W-15-23, 26
Lift Pump Motor........................8W-15-25
Liftgate Ajar Switch......................8W-15-26
Liftgate Cinch/Release Motor................8W-15-23
Liftgate Cylinder Lock Switch................8W-15-26
Liftgate Right Pinch Sensor.................8W-15-23
Low Note Horn........................8W-15-5, 6
Memory Seat/Mirror Module.................8W-15-11
Overhead Console.......................8W-15-21
Oxygen Sensor 1/2 Downstream...............8W-15-7
Park/Neutral Position Switch.................8W-15-7
Passenger Door Courtesy Lamp............8W-15-16, 20
Passenger Door Lock Switch..............8W-15-16, 20
Passenger Heated Seat Module...............8W-15-22
Passenger Power Seat Switch................8W-15-22
Passenger Power Window Switch............8W-15-16, 20
Power Folding Mirror Switch................8W-15-11
Power Liftgate Module....................8W-15-23
Power Liftgate Motor.....................8W-15-23
Power Mirror Switch......................8W-15-11
Power Outlet...........................8W-15-9
Power Window Switch.....................8W-15-15
Powertrain Control Module..................8W-15-2
Radiator Fan No. 1.......................8W-15-4
Radiator Fan No. 2.......................8W-15-4
Radiator Fan Relay.......................8W-15-4
Radiator Fan Relay No. 3...................8W-15-4
Radio...............................8W-15-13
Rear Auto Temp Control Switch...............8W-15-17
Rear Blower Front Control Switch.............8W-15-11
Rear Blower Motor Power Module...........8W-15-11, 25
Rear Blower Rear Control Switch..............8W-15-17
Rear Dome Lamp........................8W-15-21
Rear Power Outlet.......................8W-15-25
Rear Window Defogger Grid.................8W-15-26
Rear Wiper Motor.......................8W-15-26
Remote Keyless Entry Module................8W-15-10
Right B-Pillar Switch.....................8W-15-22
Right Cinch/Release Motor..................8W-15-19
Right Combination Relay...................8W-15-24
Right Cylinder Lock Switch.................8W-15-20
Right Door Speaker......................8W-15-13
Right Fog Lamp........................8W-15-5, 6
Right Front Door Ajar Switch................8W-15-20
Right Front Door Lock Motor/Ajar Switch.........8W-15-20
Right Front Park/Turn Signal Lamp.............8W-15-5
Right Full Open Switch....................8W-15-19
Right Headlamp........................8W-15-18
Right Headlamp Leveling Motor...............8W-15-6
Right High Beam Lamp....................8W-15-18
Right Liftgate Flood Lamp..................8W-15-26
Right Low Beam Lamp....................8W-15-18
Right Mid Reading Lamp...................8W-15-21
Right Park Lamp........................8W-15-18
Right Power Mirror......................8W-15-10
Right Rear Lamp Assembly.................8W-15-25
Right Rear Reading Lamp..................8W-15-21
Right Side Impact Airbag Control Module.........8W-15-12
Right Sliding Door Control Module.............8W-15-19
Right Sliding Door Latch Sensing Switch.........8W-15-19
Right Sliding Door Lock Motor...............8W-15-19
Right Sliding Door Lock Motor/Ajar Switch........8W-15-19
Right Sliding Door Motor...................8W-15-19
Right Stop/Turn Signal Relay................8W-15-24
Right Turn Signal Lamp...................8W-15-18
Right Visor/Vanity Lamp...................8W-15-21
Sentry Key Immobilizer Module...............8W-15-10
Speed Control Servo.......................8W-15-7
Traction Control Switch....................8W-15-10
Trailer Tow Connector.....................8W-15-24
Transmission Control Module.................8W-15-2
Transmission Control Relay..................8W-15-2
Transmission Range Sensor..................8W-15-7
Washer Fluid Level Switch.................8W-15-5, 6
Wiper Module..........................8W-15-17
RS8W-15 GROUND DISTRIBUTION8W-15-1
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Page 1032 of 2399
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch................ 8W-80-6
A/C Pressure Sensor.................. 8W-80-6
A/C-Heater Control C1 (MTC)........... 8W-80-6
A/C-Heater Control C2 (MTC)........... 8W-80-7
Accelerator Pedal Position Sensor
(Diesel).......................... 8W-80-7
Adjustable Pedals Module
(Except Built-Up-Export)............ 8W-80-7
Adjustable Pedals Switch
(Except Built-Up-Export)............ 8W-80-7
Airbag Control Module (ORC)........... 8W-80-8
Ambient Temp Sensor (Except Base)..... 8W-80-8
ATC Remote Sensor (ATC)............. 8W-80-8
Auto Temp Control C1................ 8W-80-9
Auto Temp Control C2................ 8W-80-9
Auto Temp Control C3................ 8W-80-9
Automatic Day/Night Mirror
(Premium/Luxury)................. 8W-80-9
Autostick Switch (Except
Built-Up-Export).................. 8W-80-10
Back-Up Lamp Switch (MTX).......... 8W-80-10
Battery Temperature Sensor (Diesel).... 8W-80-10
Blower Motor Resistor C1 (MTC)....... 8W-80-10
Blower Motor Resistor C2 (MTC)....... 8W-80-10
Body Control Module C1.............. 8W-80-11
Body Control Module C2.............. 8W-80-11
Body Control Module C3.............. 8W-80-12
Body Control Module C4.............. 8W-80-13
Body Control Module C5.............. 8W-80-14
Boost Pressure Sensor (Diesel)......... 8W-80-14
Brake Fluid Level Switch............. 8W-80-14
Brake Lamp Switch................. 8W-80-15
Brake Transmission Shift Interlock Solenoid
(EATX) ......................... 8W-80-15
C100............................. 8W-80-15
C100............................. 8W-80-16
C101............................. 8W-80-16
C101............................. 8W-80-16
C102 (2.4L)........................ 8W-80-17
C102 (2.4L)........................ 8W-80-17
C102 (3.3L/3.8L).................... 8W-80-17
C102 (3.3L/3.8L).................... 8W-80-18
C103 (Diesel)....................... 8W-80-18
C103 (Diesel)....................... 8W-80-18
C106 (Built-Up-Export)............... 8W-80-18
C106 (Built-Up-Export)............... 8W-80-19
C107 (Built-Up-Export)............... 8W-80-19
C107 (Built-Up-Export)............... 8W-80-19
C200............................. 8W-80-20
C200............................. 8W-80-22
C201............................. 8W-80-23
C201............................. 8W-80-24Component Page
C202............................. 8W-80-24
C202............................. 8W-80-24
C203 (United Kingdom).............. 8W-80-24
C203 (United Kingdom).............. 8W-80-25
C300 (LHD)........................ 8W-80-25
C300 (LHD)........................ 8W-80-25
C300 (RHD)....................... 8W-80-26
C300 (RHD)....................... 8W-80-26
C301............................. 8W-80-26
C301............................. 8W-80-26
C302............................. 8W-80-27
C302............................. 8W-80-27
C303 (LHD)........................ 8W-80-27
C303 (LHD)........................ 8W-80-28
C303 (RHD)....................... 8W-80-28
C303 (RHD)....................... 8W-80-28
C304............................. 8W-80-29
C304............................. 8W-80-29
C305............................. 8W-80-29
C305............................. 8W-80-29
C306............................. 8W-80-30
C306............................. 8W-80-30
C307............................. 8W-80-30
C307............................. 8W-80-30
C308............................. 8W-80-31
C308............................. 8W-80-31
C309............................. 8W-80-31
C309............................. 8W-80-32
C310 (Front Console)................ 8W-80-32
C310 (Front Console)................ 8W-80-32
C311 ............................. 8W-80-32
C311 ............................. 8W-80-33
C312............................. 8W-80-33
C312............................. 8W-80-34
C313 (Rear Console)................. 8W-80-34
C313 (Rear Console)................. 8W-80-34
C314 (High Line)................... 8W-80-35
C314 (High Line)................... 8W-80-35
C315 (High Line)................... 8W-80-35
C315 (High Line)................... 8W-80-36
C316 (Power Sliding Door)............ 8W-80-36
C316 (Power Sliding Door)............ 8W-80-36
C317 (Power Sliding Door)............ 8W-80-36
C317 (Power Sliding Door)............ 8W-80-37
C318 (Trailer Tow).................. 8W-80-37
C318 (Trailer Tow).................. 8W-80-37
C319 (Except Built-Up-Export/Low Line) . 8W-80-37
C319 (Except Built-Up-Export/Low Line) . 8W-80-38
C320............................. 8W-80-38
C320............................. 8W-80-38
C321............................. 8W-80-38
C321............................. 8W-80-38
RS8W-80 CONNECTOR PIN-OUTS8W-80-1
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Page 1099 of 2399
INTEGRATED POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY
CAV CIRCUIT FUNCTION
1 N21 20DB/TN LIFT PUMP RELAY CONTROL
2- -
3 T751 20YL FUSED IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT TRS REVERSE SENSE
5 N2 18DB/YL LIFT PUMP RELAY OUTPUT
6 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
8 Z114 18BK/LG GROUND
9 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A119 16RD/OR FUSED B(+)
11 C41 20LB/DG CABIN HEATER ASSIST CONTROL
12 T753 20DG/YL FUSED IGNITION SWITCH OUTPUT (START)
13 - -
14 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 20BR/WT ECM/PCM RELAY CONTROL
17 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
18 - -
19 K342 16BR/WT ECM/PCM RELAY OUTPUT
20 - -
INTEGRATED POWER MODULE C3 (GAS) - NATURAL/RED 20 WAY
CAV CIRCUIT FUNCTION
1 Z115 20BK/OR (EATX) (3.3L/3.8L) GROUND
1 Z115 18BK/OR (EATX) (2.4L) GROUND
2 F1 18PK/WT (EATX) FCM OUTPUT (UNLOCK-RUN-START)
3 T751 18YL (EATX) FUSED IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT TRS REVERSE SENSE
5 T16 18YL/OR (EATX) TRANSMISSION CONTROL RELAY OUTPUT
6 T15 18YL/BR (EATX) TRANSMISSION CONTROL RELAY CONTROL
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
8 K31 18BR FUEL PUMP RELAY CONTROL
9 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A104 18YL/RD (EATX) FUSED B(+)
11 - -
12 - -
13 D25 18WT/VT (EATX) PCI BUS (EATX)
14 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 18BR/WT AUTOMATIC SHUT DOWN RELAY CONTROL
17 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
18 K173 18BR/VT RADIATOR FAN RELAY CONTROL
19 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
20 A109 18OR/RD FUSED B(+)
8W - 80 - 68 8W-80 CONNECTOR PIN-OUTSRS
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Page 1101 of 2399
INTEGRATED POWER MODULE C7 - BLACK/RED 20 WAY
CAV CIRCUIT FUNCTION
1 C16 20DB/GY (EXCEPT
BUILT-UP-EXPORT)FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
1 C16 18DB/GY (BUILT-UP-EXPORT) FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
2 T141 20YL/OR (BUILT-UP-EXPORT) FUSED IGNITION SWITCH OUTPUT (START)
2 T751 20YL (EXCEPT
BUILT-UP-EXPORT)FUSED IGNITION SWITCH OUTPUT (START)
3 D25 20WT/VT PCI BUS
4 L13 20WT/YL (BUILT-UP-EXPORT) HEADLAMP ADJUST SIGNAL
5 K32 18DB/YL (GAS) BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
6- -
7 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
9 F201 18PK/OR FCM OUTPUT (ORC RUN-START DRIVER)
10 F214 18PK/LG FCM OUTPUT (SIACM RUN-START DRIVER)
11 A106 20LB/RD FUSED B(+)
12 - -
13 F2 18PK/WT (GAS) FCM OUTPUT (UNLOCK-RUN-START)
14 - -
15 A114 16GY/RD FUSED B(+) (I.O.D.)
16 D23 20WT/BR FLASH PROGRAM ENABLE
17 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
18 X1 16DG/BR (PREMIUM 8 SPEAKER) NAME BRAND SPEAKER RELAY OUTPUT
19 X3 20DG/VT HORN SWITCH SENSE
20 F100 18PK/VT FCM OUTPUT (ORC RUN ONLY DRIVER)
INTEGRATED POWER MODULE C8 - ORANGE 10 WAY
CAV CIRCUIT FUNCTION
1 W3 12BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED
OUTPUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
2 N1 16DB/OR (GAS) FUEL PUMP RELAY OUTPUT
3 A108 18LG/RD (BUILT-UP-EXPORT) FUSED B(+)
3 A108 18LG/RD FUSED B(+)
4 A103 18GY/RD FUSED B(+)
5 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
6 W4 12BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED
OUTPUT
7 C51 12LB/BR (AUTOMATIC
TEMPERATURE CONTROL) (3 ZONE
HVAC)FUSED REAR BLOWER MOTOR RELAY OUTPUT
8- -
9 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
10 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
8W - 80 - 70 8W-80 CONNECTOR PIN-OUTSRS
ProCarManuals.com
Page 1148 of 2399
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.Connector, ground, and splice indexes are provided.
Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
appropriate index for the proper figure number. For
items that are not shown in this section N/S is placed
in the Fig. column.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
A/C Compressor Clutch LTGY Top of A/C Compressor 9, 10, 11, 13, 14
A/C-Heater Control C1 (MTC) BK/RD Rear of Control 15, 18, 20
A/C-Heater Control C2 (MTC) BK/BL Rear of Control 15, 18, 20
A/C Pressure Transducer GY At Throttle Body 9, 11, 12, 13
Accelerator Pedal Position Sensor
(Diesel)BK At Accelerator Pedal 36
Airbag Control Module YL/RD Right Side of Instrument Panel 15, 19, 20
Ambient Temperature Sensor BK On Radiator Closure Panel 1
ATC Remote Sensor Above ATC Control N/S
Automatic Day/Night Mirror BK At Mirror N/S
Autostick Switch BK Rear of Switch 16, 17, 18
Auto Temperature Control C1
(ATC)WT Rear of Control N/S
Auto Temperature Control C2
(ATC)BK Rear of Control N/S
Auto Temperature Control C3
(ATC)Rear of Control N/S
Back-Up Lamp Switch BK On Transmission 12
Battery Temperature Sensor
(Diesel)BK At Battery N/S
Blower Motor Resistor C1 (MTC) BK Right Side of HVAC N/S
Blower Motor Resistor C2 (MTC) Right Side of HVAC N/S
Body Control Module C1 BK Under Left Instrument Panel 35, 36
Body Control Module C2 BK/GN Under Left Instrument Panel 35, 36
Body Control Module C3 BK/WT Under Left Instrument Panel 35, 36
Body Control Module C4 BK/GY Under Left Instrument Panel 15, 16, 25
Body Control Module C5 BK Under Left Instrument Panel 15, 16, 25
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-1
ProCarManuals.com
Page 1212 of 2399
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
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 material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material 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 towel. 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 material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 3)
RSENGINE 2.4L9-11
ENGINE 2.4L (Continued)
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Page 1285 of 2399
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 3). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS).Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
Fig. 3 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIGAGE
9 - 84 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com
Page 1475 of 2399
OPERATION
The crankshaft position sensor detects slots cut
into the transmission driveplate extension (Fig. 6).
There are 3 sets of slots. Each set contains 4 slots,
for a total of 12 slots (Fig. 7). Basic timing is set by
the position of the last slot in each group. Once the
Powertrain Control Module (PCM) senses the last
slot, it determines crankshaft position (which piston
will next be at TDC) from the camshaft position sen-
sor input. The 4 pulses generated by the crankshaft
position sensor represent the 69É, 49É, 29É, and 9É
BTDC marks. It may take the PCM one engine rev-
olution to determine crankshaft position.
The PCM uses crankshaft position reference to
determine injector sequence, ignition timing and the
presence of misfire. Once the PCM determines crank-
shaft position, it begins energizing the injectors in
sequence.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Disconnect the electrical connector (Fig. 8).
(4) Remove crankshaft sensor bolt.
(5) Remove the crankshaft sensor.
INSTALLATION - 2.4L
(1) Install the crankshaft sensor.
(2) Install crankshaft sensor bolt and tighten.
(3) Connect the electrical connector (Fig. 8).(4) Lower vehicle.
(5) Connect the negative battery cable.
ENGINE SPEED SENSOR
DESCRIPTION
The PCM receives a signal from the TCM and the
transaxle output speed sensor over the bus communi-
cation line to indicate vehicle speed on automatic
transmission cars. On Manual transmission cars (if
equipped) vehicle, a dedicated vehicle speed sensor is
connected to the PCM.
Fig. 6 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
Fig. 7 Timing Slots
1 - TORQUE CONVERTER DRIVE PLATE
2 - SLOTS
Fig. 8 CRANKSHAFT SENSOR 2.4L
14 - 24 FUEL INJECTIONRS
CRANKSHAFT POSITION SENSOR (Continued)
ProCarManuals.com
Page 1520 of 2399
(3) Carefully install the ignition switch. The
switch will snap over the retaining tabs (Fig. 16) .
Install mounting screw (Fig. 12).
(4) Install upper and lower shrouds.
(5) Install key cylinder (cylinder retaining tab will
depress only in the RUN position).
(6) Connect negative cable to battery.(7) Check for proper operation of ignition switch
and key-in warning switch.
LOCK CYLINDER HOUSING
DESCRIPTION - IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Unlock, Run or Start position. In
addition, the operator cannot rotate the key to the
lock position unless the shifter is in the park posi-
tion. On vehicles equipped with floor shift refer to
the - Transaxle for Automatic Transmission Shifter/
Ignition Interlock.
REMOVAL
(1) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(2) Remove the screws attaching the lower steer-
ing column cover to the instrument panel (Fig. 17),
then remove the cover from the lower instrument
panel.
Fig. 15 Ignition Switch Connectors
1 - KEY IN SWITCH
2 - PRNDL SWITCH
3 - IGNITION SWITCH
Fig. 16 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
Fig. 17 Lower Steering Column Cover Attachment
1 - PARK BRAKE RELEASE HANDLE
2 - STEERING COLUMN COVER
3 - STEERING COLUMN
4 - ATTACHING CLIP
5 - ATTACHING SCREWS
6 - HOOD RELEASE LEVER
7 - ATTACHING SCREWS
RSCOLUMN19-17
IGNITION SWITCH (Continued)
ProCarManuals.com