Glow plug CHRYSLER VOYAGER 2002 Service Manual
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Page 318 of 2399
RADIATOR FAN RELAY
DESCRIPTION
The low and high speed fan relays are mounted to
the upper radiator support above the charge air
cooler (Fig. 25).
OPERATION
The cooling system uses two fans. Both fans oper-
ate at two different speeds, low and high. Depending
on engine coolant temperature and A/C system high
side pressure, the fans operate at either low or high.
The ignition switch supplies voltage to the coil side of
the relay. When the ECM grounds the coil side of the
relay, the contacts close and the battery supplies
power to the fans.
COOLANT SYSTEM HOSES
REMOVAL
REMOVAL - UPPER RADIATOR HOSE
WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.(1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove upper radiator hose (Fig. 26).
REMOVAL - LOWER RADIATOR HOSE
WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Remove lower radiator hose (Fig. 26).
Fig. 25 RELAY LOCATIONS
1 - GLOW PLUG RELAY
2 - UPPER RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - RADIATOR FAN RELAYS
5 - UPPER RADIATOR HOSE
6 - EGR SOLENOID
Fig. 26 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE7a-29
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ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ENGINE CONTROL MODULE
DESCRIPTION..........................1
OPERATION............................1
STANDARD PROCEDURE - PCM/ECM/SKIM
PROGRAMMING - DIESEL...............2REMOVAL.............................4
INSTALLATION..........................4
ENGINE CONTROL MODULE
DESCRIPTION
The ECM is located in the left front corner of the
engine compartment attached to the radiator support
(Fig. 1).
OPERATION
The ECM has been programmed to monitor differ-
ent circuits of the diesel fuel injection system. Thismonitoring is called on-board diagnostics. Certain cri-
teria must be met for a diagnostic trouble code to be
entered into the ECM memory. The criteria may be a
range of: engine rpm, engine temperature, time or
other input signals to the ECM. If all of the criteria
for monitoring a system or circuit are met, and a
problem is sensed, then a DTC will be stored in the
ECM memory. It is possible that a DTC for a moni-
tored circuit may not be entered into the ECM mem-
ory, even though a malfunction has occurred. This
may happen when the monitoring criteria have not
been met. The ECM compares input signal voltages
from each input device with specifications (the estab-
lished high and low limits of the input range) that
are programmed into it for that device. If the input
voltage is not within the specifications and other
trouble code criteria are met, a DTC will be stored in
the ECM memory.
ECM OPERATING MODES
As input signals to the ECM change, the ECM
adjusts its response to the output devices. For exam-
ple, the ECM must calculate a different fuel quantity
and fuel timing for engine idle condition than it
would for a wide open throttle condition. There are
several different modes of operation that determine
how the ECM responds to the various input signals.
Ignition Switch On (Engine Off)
When the ignition is turned on, the ECM activates
the glow plug relay for a time period that is deter-
mined by engine coolant temperature, atmospheric
temperature and battery voltage.
Engine Start-Up Mode
The ECM uses the engine temperature sensor and
the crankshaft position sensor (engine speed) inputs
to determine fuel injection quantity.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration
and wide open throttle modes are controlled based on
all of the sensor inputs to the ECM. The ECM uses
Fig. 1 ENGINE CONTROL MODULE LOCATION-
TYPICAL
1 - BATTERY
2 - IPM (INTEGRATED POWER MODULE)
3 - ECM (ENGINE CONTROL MODULE)
4 - RETAINING BOLT
5 - RADIATOR SUPPORT
6 - CLUTCH CABLE BRACKET (LHD)
7 - CLUTCH CABLE BRACKET RETAINING BOLT (LHD)
RGELECTRONIC CONTROL MODULES8Ea-1
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Page 486 of 2399
IGNITION CONTROL
TABLE OF CONTENTS
page page
GLOW PLUG
DESCRIPTION..........................1
OPERATION............................1
GLOW PLUG RELAY
DESCRIPTION..........................1
OPERATION............................1CAMSHAFT POSITION SENSOR
DESCRIPTION..........................2
OPERATION............................2
REMOVAL.............................2
INSTALLATION..........................2
GLOW PLUG
DESCRIPTION
Glow plugs are used to help start a cold or cool
engine (Fig. 1). The glow plugs will heat up and glow
to heat the combustion chamber of each cylinder. An
individual glow plug is used for each cylinder. Each
glow plug is threaded into the left side of the cylinder
head below the cylinder head cover/intake manifold.
OPERATION
Each glow plug will momentarily draw approxi-
mately 25 amps of electrical current during the ini-
tial key ªONº cycle. This is on a cold or cool engine.
After heating the current draw will drop to approxi-
mately 9±12 amps per plug.
Total momentary cuurent draw for all four glow
plugs is approximately 100 amps on a cold engine
dropping to a total of approximately 40 amps after
the plugs are heated.
Electrical operation of the glow plugs is controlled
by two glow plug relays. Each glow plug relay con-
trols two glow plugs. Refer to glow plug relays for
more information.
GLOW PLUG RELAY
DESCRIPTION
There are two glow plug relays. These relays are
located in the Power Distribution Center (PDC) in
the engine compartment (Fig. 2).
OPERATION
When the ignition (key) switch is place in the ON
position, a signal is sent to the ECM relating current
engine coolant temperature. This signal is sent from
the engine coolant temperature sensor.
After receiving this signal, the ECM will determine
if, when and for how long of a period the glow plug
relays should be activated. This is done before, dur-
ing and after the engine is started. Whenever the
glow plug relays are activated, it will control the 12
volt 100 amp circuit for the operation of the four
glow plugs. Each relay control two glow plugs.
Fig. 1 GLOW PLUG
Fig. 2 RELAY LOCATIONS
1 - GLOW PLUG RELAY
2 - RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - COOLING FAN RELAY
5 - UPPER RADIATOR HOSE
6 - EGR SOLENOID
RGIGNITION CONTROL8Ia-1
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Page 487 of 2399
The Glow Plug lamp is tied to this circuit. Lamp
operation is also controlled by the ECM.
With a cold engine, the glow plug relays and glow
plugs may be activated for a maximum time of 200
seconds. Refer to the following Glow Plug Control
chart for a temperature/time comparison of the glow
plug relay operation.
In this chart, Pre-Heat and Post-Heat times are
mentioned. Pre-Heat is the amount of time the glow
plug relay control circuit is activated when the igni-
tion (key) is switched ON, without the engine run-
ning. Post-Heat is the amount of time the glow plug
relay control circuit is activated after the engine is
operated. The Glow Plug lamp will not be activated
during the post-heat cycle.
Engine
Coolant
Temperature
9Key ON9Wait-To
Start Lamp
9ON9
(Seconds)Pre-Heat
Cycle
(Glow
Plugs On
Seconds)Post-Heat
Cycle
(Seconds)
-30C 20 SEC. 35 SEC. 200 SEC.
-10C 8 SEC. 23 SEC. 180 SEC.
+10C 6 SEC. 21 SEC. 160 SEC.
+30C 5 SEC. 20 SEC. 140 SEC.
+40C 4 SEC. 19 SEC. 70 SEC.
+70C 1 SEC. 16 SEC. 20 SEC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The camshaft position (CMP) sensor is mounted in
the top of cylinder head cover/intake manifold at the
rear of the engine. The CMP sensor is a hall effect
device (Fig. 3).
OPERATION
The CMP sensor is a hall effect switch. A tooth
made of a ferromagnetic material is attached to the
camshaft. When this tooth passes the CMP sensor an
lectronic signal is created. This signal is then sent to
the engine control module (ECM). This signal is used
by the ECM to determine which cylinder has just
entered its compression phase.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Disconnect camshaft position sensor electrical
connector (Fig. 4).
(4) Remove sensor retaining bolt and remove sen-
sor from cylinder head cover.
INSTALLATION
(1) Lubricate O-ring and install sensor in cylinder
head cover. Torque retaining bolt to 5.4 N´m.
(2) Connect camshaft position sensor electrical
connector.
(3) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(4) Connect negative battery cable.
Fig. 3 CAMSHAFT POSITION SENSOR
Fig. 4 CAMSHAFT POSITION SENSOR LOCATION
1 - CAMSHAFT POSITION SENSOR
2 - CAMSHAFT POSITION SENSOR ELCTRICAL SENSOR
3 - FUEL INJECTOR
4 - CYLINDER HEAD COVER
5 - OIL SEPARATOR
8Ia - 2 IGNITION CONTROLRG
GLOW PLUG RELAY (Continued)
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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
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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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8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch............... 8W-30-18
A/C Compressor Clutch Relay........ 8W-30-3, 18
A/C Pressure Sensor............ 8W-30-9, 15, 25
Accelerator Pedal Position Sensor....... 8W-30-32
Adjustable Pedals Module............. 8W-30-17
Adjustable Pedals Switch............. 8W-30-17
Auto Shut Down Relay.... 8W-30-2, 5, 7, 8, 12, 13
Battery...................... 8W-30-2, 18, 26
Battery Temperature Sensor........... 8W-30-25
Body Control Module.............. 8W-30-4, 19
Boost Pressure Sensor................ 8W-30-25
Brake Lamp Switch............. 8W-30-6, 21, 31
Cabin Heater Assist................. 8W-30-22
Camshaft Position Sensor........ 8W-30-7, 13, 24
Clockspring...................... 8W-30-3, 23
Clutch Pedal Upstop Switch........... 8W-30-30
Crank Case Ventilation Heater......... 8W-30-19
Crankshaft Position Sensor....... 8W-30-7, 13, 24
Data Link Connector............... 8W-30-4, 22
Diagnostic Junction Port......... 8W-30-4, 23, 17
Dosing Pump....................... 8W-30-22
ECM/PCM Relay........ 8W-30-18, 20, 24, 26, 28
EGR Solenoid.................... 8W-30-5, 28
Engine Control Module . . . 8W-30-18, 19, 20, 21, 22,
23, 24, 25, 26, 27, 28, 29, 30, 31, 32
Engine Coolant Temp Sensor...... 8W-30-9, 15, 25
Engine Oil Pressure Sensor........... 8W-30-21
Engine Oil Pressure Switch............ 8W-30-6
Engine Oil Temperature Sensor........ 8W-30-24
Evap/Purge Solenoid.................. 8W-30-3
Front Control Module...... 8W-30-3, 4, 17, 22, 30
Fuel Heater........................ 8W-30-29
Fuel Heater Relay................ 8W-30-19, 29
Fuel Injector No. 1............. 8W-30-8, 12, 27
Fuel Injector No. 2............. 8W-30-8, 12, 27
Fuel Injector No. 3............. 8W-30-8, 12, 27
Fuel Injector No. 4............. 8W-30-8, 12, 27
Fuel Injector No. 5.................. 8W-30-12
Fuel Injector No. 6.................. 8W-30-12
Fuel Pressure Sensor................ 8W-30-31
Fuel Pressure Solenoid............... 8W-30-20
Fuel Pump Module................ 8W-30-4, 19
Fuel Pump Relay.................... 8W-30-4
Fuse 14........................... 8W-30-17
Fuse 15........................ 8W-30-22, 29
Fuse 16 . . 8W-30-2, 5, 7, 8, 12, 13, 18, 20, 24, 26, 28
Fuse 17.................... 8W-30-2, 4, 19, 29Component Page
Fuse 18........................ 8W-30-18, 17
Fuse 26........................... 8W-30-31
Fuselink.......................... 8W-30-26
G100.............................. 8W-30-2
G101........................... 8W-30-2, 18
G103................... 8W-30-5, 6, 18, 19, 22
G300..................... 8W-30-6, 17, 21, 30
G302........................ 8W-30-4, 19, 29
Generator....................... 8W-30-2, 19
Glow Plug No. 1.................... 8W-30-26
Glow Plug No. 2.................... 8W-30-26
Glow Plug No. 3.................... 8W-30-26
Glow Plug No. 4.................... 8W-30-26
Glow Plug Relay.................... 8W-30-26
Idle Air Control Motor............. 8W-30-11, 14
Ignition Coil..................... 8W-30-7, 13
Ignition Switch..................... 8W-30-16
Inlet Air Temperature Sensor....... 8W-30-10, 14
Integrated Power
Module.......... 8W-30-2, 3, 4, 5, 7, 8, 12, 13,
18, 19, 20, 22, 24, 26, 28, 29, 30, 31
Knock Sensor.................... 8W-30-9, 15
Leak Detection Pump................ 8W-30-16
Left Speed Control Switch........... 8W-30-3, 23
Lift Pump Motor.................... 8W-30-29
Lift Pump Relay.................... 8W-30-29
Manifold Absolute Pressure Sensor.... 8W-30-9, 15
Mass Air Flow Sensor................ 8W-30-20
Oxygen Sensor 1/1 Upstream........... 8W-30-5
Oxygen Sensor 1/2 Downstream......... 8W-30-5
Park/Neutral Position Switch.......... 8W-30-11
Power Mirror Switch................. 8W-30-17
Powertrain Control Module . 8W-30-2, 3, 4, 5, 6, 10,
11, 7, 8, 9, 12, 13, 14, 15, 16
Radiator Fan Relay................... 8W-30-3
Radiator Fan Relay No. 1............. 8W-30-31
Radiator Fan Relay No. 2............. 8W-30-31
Radiator Fan Relay No. 3............. 8W-30-31
Right Speed Control Switch......... 8W-30-3, 23
Speed Control Servo.................. 8W-30-6
Starter Motor Relay............... 8W-30-4, 19
Throttle Position Sensor........... 8W-30-10, 14
Torque Converter Clutch Solenoid....... 8W-30-16
Transmission Control Module . . 8W-30-7, 10, 11, 14
Transmission Range Sensor......... 8W-30-11, 14
Vehicle Speed Sensor............ 8W-30-7, 11, 28
Water In Fuel Sensor................ 8W-30-30
RS8W-30 FUEL/IGNITION SYSTEM8W-30-1
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Page 1034 of 2399
Component Page
Glove Box Lamp.................... 8W-80-63
Glow Plug Relay (Diesel).............. 8W-80-63
Halo Lamp........................ 8W-80-63
Headlamp Switch................... 8W-80-64
Headlamp Washer Pump Motor
(Built-Up-Export)................. 8W-80-64
High Note Horn.................... 8W-80-64
Hood Ajar Switch................... 8W-80-64
Idle Air Control Motor (2.4L).......... 8W-80-64
Idle Air Control Motor (3.3L/3.8L)....... 8W-80-65
Ignition Coil (2.4L).................. 8W-80-65
Ignition Coil (3.3L/3.8L).............. 8W-80-65
Ignition Switch..................... 8W-80-65
Inlet Air Temperature Sensor.......... 8W-80-65
Input Speed Sensor (EATX)........... 8W-80-66
Instrument Cluster.................. 8W-80-66
Instrument Panel Switch Bank......... 8W-80-66
Integrated Power Module C1.......... 8W-80-67
Integrated Power Module C2.......... 8W-80-67
Integrated Power Module C3 (Diesel).... 8W-80-68
Integrated Power Module C3 (Gas)...... 8W-80-68
Integrated Power Module C4.......... 8W-80-69
Integrated Power Module C5.......... 8W-80-69
Integrated Power Module C6.......... 8W-80-69
Integrated Power Module C7.......... 8W-80-70
Integrated Power Module C8.......... 8W-80-70
Integrated Power Module C9.......... 8W-80-71
Knock Sensor (2.4L)................. 8W-80-71
Knock Sensor (3.3L/3.8L) (Except
Built-Up-Export).................. 8W-80-71
Leak Detection Pump (Except
Built-Up-Export).................. 8W-80-71
Left B-Pillar Switch (Power
Sliding Door)..................... 8W-80-72
Left Cinch/Release Motor (Power
Sliding Door)..................... 8W-80-72
Left Combination Relay (Trailer Tow).... 8W-80-72
Left Cylinder Lock Switch............. 8W-80-72
Left Door Speaker................... 8W-80-72
Left Fog Lamp (Built-Up-Export)....... 8W-80-73
Left Fog Lamp (Except
Built-Up-Export).................. 8W-80-73
Left Front Door Ajar Switch (Base)...... 8W-80-73
Left Front Door Lock Motor/Ajar Switch
(Except Base).................... 8W-80-73
Left Front Park/Turn Signal Lamp
(Except Built-Up-Export)........... 8W-80-73
Left Front Wheel Speed Sensor......... 8W-80-74
Left Full Open Switch
(Power Sliding Door)............... 8W-80-74
Left Headlamp (Except Built-Up-Export) . 8W-80-74
Left Headlamp Leveling Motor
(Built-Up-Export)................. 8W-80-74
Left High Beam Lamp
(Built-Up-Export)................. 8W-80-74Component Page
Left Instrument Panel Speaker......... 8W-80-75
Left Liftgate Flood Lamp............. 8W-80-75
Left Low Beam Lamp (Built-Up-Export) . . 8W-80-75
Left Mid Reading Lamp
(Premium/Luxury)................. 8W-80-75
Left Park Lamp (Built-Up-Export)...... 8W-80-75
Left Power Mirror................... 8W-80-76
Left Rear Lamp Assembly............. 8W-80-76
Left Rear Pillar Speaker.............. 8W-80-76
Left Rear Reading Lamp (Luxury)...... 8W-80-76
Left Rear Speaker................... 8W-80-77
Left Rear Vent Motor................ 8W-80-77
Left Rear Wheel Speed Sensor......... 8W-80-77
Left Remote Radio Switch............. 8W-80-77
Left Repeater Lamp (Built-Up-Export) . . . 8W-80-77
Left Seat Airbag.................... 8W-80-78
Left Side Impact Airbag Control Module . . 8W-80-78
Left Sliding Door Control Module C1
(Power Sliding Door)............... 8W-80-78
Left Sliding Door Control Module C2
(Power Sliding Door)............... 8W-80-78
Left Sliding Door Latch Sensing Switch
(Power Sliding Door)............... 8W-80-79
Left Sliding Door Lock Motor
(Power Sliding Door)............... 8W-80-79
Left Sliding Door Lock Motor/Ajar Switch
(Manual Sliding Door).............. 8W-80-79
Left Sliding Door Motor
(Power Sliding Door)............... 8W-80-79
Left Speed Control Switch............ 8W-80-79
Left Stop/Turn Signal Relay (Trailer Tow) . 8W-80-80
Left Turn Signal Lamp (Built-Up-Export) . 8W-80-80
Left Visor/Vanity Lamp
(Premium/Luxury)................. 8W-80-80
License Lamp (Manual Release)........ 8W-80-80
License Lamp (Power Liftgate)......... 8W-80-80
License Lamp (Power Release)......... 8W-80-81
Lift Pump Motor (Diesel)............. 8W-80-81
Liftgate Ajar Switch (Manual Release) . . . 8W-80-81
Liftgate Ajar Switch (Power Release).... 8W-80-81
Liftgate Cinch/Release Motor
(Power Liftgate).................. 8W-80-81
Liftgate Cylinder Lock Switch.......... 8W-80-82
Liftgate Left Pinch Sensor
(Power Liftgate).................. 8W-80-82
Liftgate Right Pinch Sensor
(Power Liftgate).................. 8W-80-82
Low Note Horn..................... 8W-80-82
Manifold Absolute Pressure Sensor
(Gas)........................... 8W-80-82
Mass Air Flow Sensor (Diesel)......... 8W-80-83
Memory Seat/Mirror Module C1........ 8W-80-83
Memory Seat/Mirror Module C2........ 8W-80-84
Memory Seat/Mirror Module C3........ 8W-80-84
Memory Seat/Mirror Module C4........ 8W-80-84
RS8W-80 CONNECTOR PIN-OUTS8W-80-3
ProCarManuals.com
Page 1087 of 2399
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 - -
58 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND
59 - -
60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20BR/WT ECM/PCM RELAY CONTROL
62 - -
63 D21 20WT/BR SCI TRANSMIT
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
67 - -
68 - -
69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
71 - -
72 N21 20DB/TN LIFT PUMP RELAY CONTROL
73 - -
74 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
75 - -
76 - -
77 K152 20DB/WT GLOW PLUG RELAY CONTROL
78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
79 - -
80 K87 20BR FUEL PRESSURE SOLENOID CONTROL
81 K87 20BR FUEL PRESSURE SOLENOID CONTROL
8W - 80 - 56 8W-80 CONNECTOR PIN-OUTSRS
ProCarManuals.com
Page 1094 of 2399
FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K342 16BR/WT ECM/PCM RELAY OUTPUT
2 K87 16BR FUEL PRESSURE SOLENOID CONTROL
FUEL PUMP MODULE - LT. GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 Z201 16BK/OR (GAS) GROUND
2 Z201 18BK/OR (RHD/DIESEL) GROUND
2 Z201 20BK/DB (LHD/DIESEL) (GAS) GROUND
3 N4 18DB/WT FUEL LEVEL SENSOR SIGNAL
4 N1 16DB/OR (GAS) FUEL PUMP RELAY OUTPUT
GENERATOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
1 K342 16BR/WT (GAS) AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K20 14BR/GY (DIESEL) GENERATOR FIELD CONTROL
2 K20 18BR/GY (GAS) GENERATOR FIELD CONTROL
GLOVE BOX LAMP - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 M28 20YL/TN GLOVE BOX LAMP DRIVER
2 Z328 20BK/TN GROUND
GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 A202 10RD/WT FUSED B(+)
2 K152 20DB/WT GLOW PLUG RELAY CONTROL
3 K342 16BR/WT ECM/PCM RELAY OUTPUT
4 K154 10BR/OR GLOW PLUG RELAY OUTPUT
HALO LAMP - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 Z326 20BK/OR GROUND
2 M26 20YL/DB HALO LAMP DRIVER
RS8W-80 CONNECTOR PIN-OUTS8W-80-63
ProCarManuals.com