headlamp CHRYSLER VOYAGER 2003 Repair Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2003Pages: 2177, PDF Size: 59.81 MB
Page 1077 of 2177
MULTI-FUNCTION SWITCH - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 W52 22BR/YL FRONT WIPER SWITCH MUX
2 G902 22VT/LB MULTI-FUNCTION SWITCH MUX RETURN
3 L305 20WT/LB TURN SIGNAL SWITCH MUX
4 G194 22VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
NATURAL VACUUM LEAK DETECTION ASSEMBLY (2.4L EXCEPT EXPORT) - LT. GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z166 18BK/WT GROUND
2 K107 20VT/WT NVLD SWITCH SIGNAL
3 K106 20VT/LB NVLD SOL CONTROL
OUTPUT SPEED SENSOR (EATX) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 T13 18DG/VT SPEED SENSOR GROUND
2 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 G23 20VT/DB (EXCEPT SUNROOF) SLIDING DOORS OVERHEAD SWITCH MUX
1 G23 22VT/DB (SUNROOF) SLIDING DOORS OVERHEAD SWITCH MUX
2 G25 20VT/TN (EXCEPT SUNROOF) LIFTGATE SWITCH MUX
2 G25 22VT/TN (SUNROOF) LIFTGATE SWITCH MUX
3 D25 20WT/VT PCI BUS
4 Z113 20BK/DB GROUND
5 A114 20GY/RD FUSED B(+) (I.O.D.)
6 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
7 Z13 20BK/WT GROUND
8 E15 20OR/DB ASH/RECEIVER LAMP FEED
9- -
10 - -
11 L24 20BK/GY (EXCEPT EXPORT/
PREMIUM/LUXURY)AUTOMATIC HEADLAMP SWITCH SENSOR
12 L1 20BK/WT (PREMIUM/LUXURY) BACK-UP LAMP FEED
8W - 80 - 96 8W-80 CONNECTOR PIN-OUTSRS
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Page 1103 of 2177
RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Q52 20OR RIGHT FULL OPEN SWITCH SENSE
2 Z76 20BK/YL GROUND
RIGHT HEADLAMP (EXCEPT EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L44 16WT/TN RIGHT LOW BEAM DRIVER
2 Z344 16BK/TN GROUND
3 L34 16WT/GY RIGHT HIGH BEAM DRIVER
RIGHT HEADLAMP LEVELING MOTOR (EXPORT) - WHITE 3 WAY
CAV CIRCUIT FUNCTION
1 Z203 16BR GROUND
2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT)
3 L13 16RD HEADLAMP ADJUST SIGNAL
8W - 80 - 122 8W-80 CONNECTOR PIN-OUTSRS
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Page 1117 of 2177
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Body Control Module C3 BK/WT Under Left Instrument Panel 40, 41
Body Control Module C4 BK/GY Under Left Instrument Panel 19, 20, 29
Body Control Module C5 BK Under Left Instrument Panel 19, 20, 29
Boost Pressure Sensor (Diesel) BK Top Left of Engine N/S
Brake Fuid Level Switch BK On Master Cylinder 6
Brake Lamp Switch BK At Top Of Brake Pedal 40, 41
Brake Transmission Shift
Interlock Solenoid (EATX)BK Near Steering Column 19, 20, 21, 30
C100 BK Left Fender Shield 5, 11
C101 LTGY Left Fender Shield 5
C102 (2.4L) BK Top Front of Engine 11
C102 (3.3/3.8L) BK At Fuel Rail 17
C103 (Diesel) BK Left Side Engine Compartment 5
C106 (Export) BK Near Left Headlamp Leveling Motor N/S
C107 (Export) BK Near Right Headlamp Leveling
MotorN/S
C110 (2.4L) BK Left Front Engine 11
C111 (2.4L) BK Left Front Engine 11
C200 GY Left Side Instrument Panel 19, 20, 29, 40, 41
C201 YL Left Side Instrument Panel 19, 20, 29, 40, 41
C202 GY Right Side Instrument Panel A/C
Heatrer Unit19, 23, 28
C203 (United Kingdom) WT Right Side of Instrument Panel N/S
C204 Rear of Radio 49
C300 (LHD) BK Left Front Door Lower 35, 42
C300 (RHD) BK Right Front Door Lower N/S
C301 LTGY Left Front Door Upper 35, 42
C302 LTGY Right Front Door Upper 8, 38, 43
C303 (LHD) BK Right Front Door Lower 8, 43
C303 (RHD) BK Left Front Door Lower 38, 43
C304 YL Left Wire Track Seat to Body 31
C305 GY Left Wire Track Seat to Body 31
C306 YL Right Wire Track Seat to Body 32
C307 GY Right Wire Track Seat to Body 32
C308 BL Left Rear Sliding Door 39
C309 GN Right Rear Sliding Door 31, 32, 38
C310 BK At Front Console 33
C311 GY Rear A/C Switch N/S
C312 GY At Dome Lamp 32, 38, 49
C313 BK At Rear Console 33
C314 BK Left Side Liftgate 48
C315 BK Right Side Liftgate 48
C316 BK Wire Track to Sliding Door N/S
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1120 of 2177
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 15
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 16
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12
EVAP/Purge Solenoid BK Right Motor Mount 10, 17
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 19, 22, 24
Front Intrusion Sensor BK At Sensor N/S
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 15
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 15
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 15
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 15
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 33
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug Relay (Diesel) BK Near Battery N/S
Headlamp Switch BK Rear of Switch 19, 20, 29
Headlamp Washer Pump Motor At Motor 3
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump
(Diesel)Rear of Pump 15
Hood Ajar Switch BK Left Fender 6
Idle Air Control Motor (2.4L) BK On Throttle Body 10, 11
Idle Air Control Motor (3.3/3.8L) BK On Throttle Body 17
Ignition Coil 2.4L BK Top of Valve Cover 10, 11
Ignition Coil 3.3L, 3.8L DKGY Top of Engine 18
Ignition Switch BK Rear of Switch at Steering Column 19, 20, 21, 22, 30
Inlet Air Temperature Sensor BK Top Left of Engine 9, 10, 11
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1121 of 2177
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Input Speed Sensor GY Front of Transmission 14
Instrument Cluster BK Rear of Cluster 19, 20, 27
Instrument Panel Switch Bank BK Right Center of Instrument Panel 19, 22, 24
Instrument Panel Power Outlet NAT Center of Instrument Panel N/S
Integrated Power Module C1 LTGN Left Fender Shield 6, 7
Integrated Power Module C2 GN/BL Left Fender Shield 6, 7
Integrated Power Module C3
(Diesel)YL/RD Left Fender Shield 6, 7
Integrated Power Module C3
(Gas)NAT/RD Left Fender Shield 6, 7, 11
Integrated Power Module C4 BL Left Fender Shield 6, 7, 11
Integrated Power Module C5 BK Left Fender Shield 6, 7
Integrated Power Module C6 NAT Left Fender Shield 6, 7
Integrated Power Module C7 BK/RD Left Fender Shield 6, 7
Integrated Power Module C8 OR Left Fender Shield 6, 7
Integrated Power Module C9 BK Left Fender Shield 6, 7
Knock Sensor GY Front of Cylinder Block 11
Leak Detection Pump LTGY At Pump 10, 11 18
Left B Pillar Switch GY Left B Pillar 39
Left Cinch/Release Motor GY Left Sliding Door N/S
Left Combination Relay BK Left Rear Quarter Panel N/S
Left Cylinder Lock Switch BK At Switch 42
Left Door Speaker BK At Speaker 42
Left Fog Lamp WT At Lamp N/S
Left Front Door Ajar Switch BK At Switch 42
Left Front Door Lock Motor/Ajar
SwitchBK Left Door 42
Left Front Park/Turn Signal Lamp BK At Lamp 1, 5
Left Front Wheel Speed Sensor BK Left Fender Side Shield 5, 11
Left Full Open Switch BK Left Sliding Door N/S
Left Headlamp BK At Lamp 1, 5
Left Headlamp Leveling Motor WT At Motor N/S
Left High Beam Lamp BK At Lamp N/S
Left Instrument Panel Speaker BK At Speaker 19, 20, 26
Left Liftgate Flood Lamp GY At Lamp 48
Left Low Beam Lamp BK At Lamp N/S
Left Mid Reading Lamp GY At Lamp N/S
Left Park Lamp BK At Lamp 5
Left Power Mirror BK At Mirror 26
Left Rear Lamp Assembly BK At Lamp 46
Left Rear Pillar Speaker BK Left of Liftgate 46
Left Rear Reading Lamp GY At Lamp N/S
Left Rear Speaker BK At Speaker 46
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1125 of 2177
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Recirculation Door Actuator GY Right Side of HVAC N/S
Remote Keyless Entry Antenna
(JAPAN)BK Right Upper Instrument Panel 27
Remote Keyless Entry Module BK/RD Top Left of I.P. 19, 20
Right B-Pillar Switch GY Right B Pillar 38
Right Cinch/Release Motor GY Rear of Sliding Door 44
Right Combination Relay BK Left Quarter Panel N/S
Right Cylinder Lock Switch BK Right Front Door 43
Right Door Speaker BK/RD At Speaker N/S
Right Fog Lamp WT At Lamp 3
Right Front Door Ajar Switch BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
SwitchBK Right Front Door 43
Right Front Park/Turn Signal
LampBK At Lamp 1, 3
Right Front Wheel Speed Sensor GY Right Fender Side Shield 3,10, 16, 17
Right Full Open Switch BK Right Sliding Door 44
Right Headlamp BK At Lamp 1, 3
Right Headlamp Leveling Motor WT At Right Headlamp N/S
Right High Beam Lamp BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 19, 22, 23
Right Liftgate Flood Lamp BK At Lamp 48
Right Low Beam Lamp BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
Right Park Lamp BK AT Lamp N/S
Right Power Mirror BK At Mirror 19, 23, 27
Right Rear Lamp Assembly BK At Lamp 47
Right Rear Pillar Speaker BK At Speaker 47
Right Rear Reading Lamp GY At Lamp N/S
Right Rear Speaker BK/RD At Speaker 47
Right Rear Vent Motor NAT At Motor 47
Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 47
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater Lamp GY Right Front Fender 38
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Airbag Control
ModuleYL/RD Right B Pillar 38
Right Sliding Door Control
Module C1BK Rear of Door 44, 45
Right Sliding Door Control
Module C2BK/RD Rear of Door 44, 45
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 44
Right Sliding Door Lock Motor BK Rear of Door 44
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1126 of 2177
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Sliding Door Lock
Motor/Ajar SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 44
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Immobilizer Module BK At Steering Column 19, 20, 21, 22, 30
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission 14, 18
Speed Control Servo BK Near Controller Antilock Brake 11, 18
Sunroof Module BK At Sunroof N/S
Sunroof Switch Nat Near Overhead Console N/S
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel
Near SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor GY On Throttle Body 10, 11, 17
Torque Converter Clutch Solenoid BK Front of Transmission 11
Traction Control Switch BK Rear of Swtich 20, 21, 30
Trailer Tow Connector BK Left Quarter Panel N/S
Transmission Control Module BK Left Engine Compartment 5
Transmission Range Sensor GY Top of Transmission 14, 18
Turbo boost Pressure Sensor On Cylinder Block 15
Vehicle Speed Sensor BK Rear of Transmission 10, 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 11, 13
G102 Left Headlamp Area 1
G103 Above Starter 11, 13
G200 Right Side of Instrument Panel 19, 23, 28
G201 Right Side of Instrument Panel 19, 23, 28
G202 Near Radio N/S
G300 Left B Pillar 31
G301 Right B Pillar 32, 38
G302 Left Rear Quarter 46
G400 Liftgate Ground N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1128 of 2177
SPLICE NUMBER LOCATION FIG.
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S126 In Right Headlamp Leveling Assembly N/S
S127 (2.5L) In T/O for Engine Starter Motor N/S
S128 (2.5L) Near T/O for Engine Starter Motor 15
S129 (2.5L) Near T/O for Battery (+) N/S
S130 (2.5L) Near T/O for Battery (+) N/S
S131 Near T/O for Transmission Control Module 11
S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S
S132 (2.5L) Near T/O for Battery (+) N/S
S133 (2.4L) Near T/O for Integrated Power Module C3 11
S134 (2.5L) IN T/O for Engine Control Module 15
S135 (2.5L) Near T/O for Glow Plug No.2 15
S136 (2.5L) In T/O for Radiator Fan Relays 2
S137 (2.5L) Near T/O for A/C Compressor Clutch 15
S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 1
S139 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C116
S141 (2.4L) Near T/O for Battery(-) 11
S141 (2.5L) Near T/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 18
S143 (2.5L) Near T/O for Engine Control Module C1 15
S143 (3.3L/3.8L) Near T/O for Integrated Power Module - C3 N/S
S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10315
S148 (2.5L) Near T/O for Engine Starter Motor 15
S149 (3.3L/3.8L) Near T/O for Transmission Control Module 5
S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10315
S151 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S152 (2.5L) Near T/O for Radiator Fan No.1 1
S157 (2.5L) Near T/O for Glow Plug No.1 15
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (2.5L) In T/O for Engine Control Module C1 15
S188 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S201 In T/O to Instrument Panel Speaker 19, 25
S202 Near T/O for Instrument Panel Switch Bank 19, 25
S203 Near T/O for Instrument Panel Switch Bank 19, 25
S204 Near T/O to Instrument Panel Speaker 19, 25
S205 Near T/O for C201 19
S206 Near T/O for Instrument Cluster 19
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1131 of 2177
Fig. 1 HEADLAMP CONNECTORS
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1348 of 2177
FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................3INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............4
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................9
INSTALLATION.........................11
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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