relay CHRYSLER VOYAGER 2004 Service Manual

THROTTLE POSITION SENSOR (GAS) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K22 18BR/OR TP NO. 1 SIGNAL
3 F855 20PK/YL (2.4L) 5 VOLT SUPPLY
3 F855 18PK/YL (3.3L/3.8L) 5 VOLT SUPPLY
TRACTION CONTROL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B27 20DG/WT TRACTION CONTROL SWITCH SENSE
2 Z427 20BK/WT GROUND
TRAILER TOW CONNECTOR (EXCEPT EXPORT)-4WAY
CAV CIRCUIT FUNCTION
1 L62 18LG RIGHT REAR TURN SIGNAL DRIVER
2 Z362 18WT GROUND
3 L77 18BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
4 L63 18YL LEFT REAR TURN SIGNAL DRIVER
TRANSMISSION RANGE SENSOR - DK. GRAY 10 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 T13 18DG/VT SPEED SENSOR GROUND
4 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
5- -
6- -
7 T1 18DG/LB TRS T1 SENSE
8 T3 18DG/DB TRS T3 SENSE
9 T42 18DG/YL TRS T42 SENSE
10 T41 18DG/GY TRS T41 SENSE
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 133

TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
2 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
3 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
4 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
5 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
6 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
7 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
8 T19 18YL/DB 2-4 SOLENOID CONTROL
VEHICLE SPEED SENSOR (MTX) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F855 20PK/YL (2.4L) 5 VOLT SUPPLY
1 F202 18PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 K900 18DB/DG (2.4L) SENSOR GROUND
2 K900 20DB/DG (DIESEL) SENSOR GROUND
3 N7 18DB/OR (2.4L) VEHICLE SPEED SIGNAL
3 N7 20DB/OR (DIESEL) VEHICLE SPEED SENSOR SIGNAL
WASHER FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z401 18BK/LB (EXCEPT EXPORT) GROUND
1 Z401 20BK/LB (EXPORT) GROUND
2 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
WASHER PUMP MOTOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL
2 W10 18BR FRONT WASHER PUMP MOTOR CONTROL
8W - 80 - 134 8W-80 CONNECTOR PIN-OUTSRS

WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 F853 20RD WATER IN FUEL SENSOR SIGNAL
2 K900 18RD SENSOR GROUND
WIPER MODULE - DK. GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUT-
PUT
2 W7 20BR/GY WIPER PARK SWITCH SENSE
3 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUT-
PUT
4 Z103 14BK/WT GROUND
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 135

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 10, 11, 15, 17, 18
A/C-Heater Control C1 (MTC) BK/RD Rear of Control 20, 23, 25
A/C-Heater Control C2 (MTC) BK/BL Rear of Control 20, 23, 25
A/C Pressure Sensor GY At Throttle Body 10, 15, 16, 17
Accelerator Pedal Position
Sensor (Diesel)BK At Accelerator Pedal 42
Adjustable Pedals Module
(Except Export)Near Brake Lamp Switch N/S
Adjustable Pedals Switch (Except
Export)DKGY Left Side Kick Panel 41
Adjustable Pedals Relay (Except
Export)Left Side Engine Compartment 6
Airbag Control Module (ORC)
(Base)YL/RD Right Side of Instrument Panel 24
Airbag Control Module C1
(ORC)(Premium)YL Right Side Instrument Panel N/S
Airbag Control Module C2
(ORC)(Premium)YL Right Side Instrument Panel 20, 24
Ambient Temperature Sensor
(Except Base)BK On Radiator Closure Panel 1
ATC Remote Sensor Above ATC Control N/S
Automatic Day/Night Mirror BK At Mirror N/S
Auto Temp Control C1 NAT Rear of Control 20
Auto Temp Control C2 BK Rear of Control 20
Auto Temp Control C3 Rear of Control N/S
Back-Up Lamp Switch BK On Transmission 16
Battery Temperature Sensor BK At Battery N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-1

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Control Module C2
(Diesel)BK Right Side of Engine N/S
Engine Coolant Temp Sensor
(Gas)BK On Cylinder Block N/S
Engine Coolant Temp 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, 18
EVAP/Purge Solenoid (Gas) 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 20, 23, 25
Front Control Module BK In Integrated Power Module N/S
Front Intrusion Sensor (United
Kingdom)BK At Sensor N/S
Front Reading Lamps/Switch BK At Switch N/S
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 34
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug Relay (Diesel) BK Near Transmission 15, 16
Headlamp Switch BK Rear of Switch 20, 21, 30
Headlamp Washer Pump Motor
(Export)BK At Motor 3
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump
(Diesel)Rear of Pump 15
Hood Ajar Switch (Export) BK Left Fender 6
Idle Air Control Motor (Gas) BK On Throttle Body 10, 11 17
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Liftgate Right Pinch Sensor
(Power Liftgate)BK Right Side of Liftgate 49
Low Note Horn BK Left Frame Rail 5
Manifold Absolute Pressure
Sensor (Gas)BK On Intake N/S
Mass Air Flow Sensor (Diesel) OR Top of Engine 15, 16
Memory Seat/Mirror Module C1 GY Under Driver Seat N/S
Memory Seat/Mirror Module C2 GY Under Driver Seat N/S
Memory Seat/Mirror Module C3 WT Under Driver Seat N/S
Memory Seat/Mirror Module C4 GY Under Driver Seat N/S
Memory Seat Front Vertical Motor RD Under Seat N/S
Memory Seat Front Vertical
Position SensorBK Under Seat N/S
Memory Seat Horizontal Motor BK Under Seat N/S
Memory Seat Horizontal Position
SensorBK Under Seat N/S
Memory Seat Rear Vertical Motor RD Under Seat N/S
Memory Seat Rear Vertical
Position SensorBK Under Seat N/S
Memory Seat Recliner Motor GN Under Seat N/S
Memory Seat Recliner Position
SensorBK Under Seat N/S
Memory Set Switch BK At Switch Driver Door 43
Message Center (Highline) WT Rear of Message Center 20, 21, 28
Mode Door Actuator GY Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 20, 21, 22, 23, 31
Natural Vacuum Leak Detection
Assembly (Except Export)LTGY Top of Engine 12
Output Speed Sensor GY Front of Transmission 14, 18, 19
Overhead Console (Except Base) BK Front of Console N/S
Oxygen Sensor 1/1 Upstream
(Gas)BK Rear of Engine 11, 12, 18
Oxygen Sensor 1/2 Downstream
(Gas)BK Rear of Engine 11, 12,18
Passenger Airbag YL Passenger Side of Instrument Panel 20, 23, 24 29
Passenger Blend Door Actuator GY On HVAC N/S
Passenger Door Courtesy Lamp GY At Lamp 44
Passenger Door Lock Switch BK At Switch 44
Passenger Folding Mirror Relay
(Export)BL Left Kick Panel 7
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module
C1GY At Heated Seat N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Passenger Heated Seat Module
C2GY At Heated Seat Back N/S
Passenger Heated Seat Module
C3GN At Heated Seat N/S
Passenger Power Seat Front
Riser MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear
Riser MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 44
Passenger Power Window Switch BK At Switch 44
Passenger Seat Belt Switch On Seat Harness N/S
Passenger Seat Belt Tensioner On Seat Harness N/S
Power Folding Mirror Switch
(Export)BK Near Steering Column 31
Power Liftgate Module C1 BK Left Quarter 46, 47
Power Liftgate Module C2 Left Quarter 46, 47
Power Liftgate Motor BK Left Quarter 47
Power Mirror Switch BK Rear of Switch 30
Power Outlet (Except Lowline) BK Instrument Panel 20, 23, 25
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 BK Left Front Engine Compartment 11
Powertrain Control Module C2 BK Left Front Engine Compartment 11
Powertrain Control Module C3 BK Left Front Engine Compartment 11
Powertrain Control Module C4
(EATX)DKGN Left Front Engine Compartment 11
Power Window Circuit Breaker GY Left Side Kick Panel 41 42
Power Window Switch (LHD
Lowline)BK Driver Door 43
Radiator Fan No.1 (Gas) BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 1
Radiator Fan No.2 (Gas) BK Right Side At Motor 1, 2
Radiator Fan No.2 (Diesel) GY Right Side At Motor 1, 2
Radiator Fan Relay (Gas) Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1
(Diesel)BL Left Front Engine Compartment 2
Radiator Fan Relay No. 2
(Diesel)BL Left Front Engine Compartment 2
Radiator Fan Relay No. 3
(Diesel)BL Left Front Engine Compartment 2
Radio C1 Rear of Radio 20
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Front Park/Turn Signal
Lamp (Except Export)BK At Lamp 1, 3
Right Front Wheel Speed Sensor GY Right Fender Side Shield 3,10, 16, 17
Right Full Open Switch (Power
Sliding Door)BK Right Sliding Door 45
Right Headlamp (Except Export) BK At Lamp 1, 3
Right Headlamp Leveling Motor
(Export)WT At Right Headlamp N/S
Right High Beam Lamp (Export) BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 20, 23, 24
Right Liftgate Flood Lamp GY At Lamp 49
Right Low Beam Lamp (Export) BK At Right Headlamp N/S
Right Mid Reading Lamp
(Premium/ Luxury)GY At Lamp N/S
Right Park Lamp (Export) BK AT Lamp N/S
Right Power Mirror BK At Mirror 20, 24, 28
Right Rear Lamp Assembly BK At Lamp 48
Right Rear Pillar Speaker BK At Speaker 48
Right Rear Reading Lamp
(Luxury)GY At Lamp N/S
Right Rear Speaker (Highline) BK/RD At Speaker 48
Right Rear Speaker (Lowline) At Speaker N/S
Right Rear Vent Motor NAT At Motor 48
Right Rear Wheel Speed Sensor BK Right Rear of Floor Pan 48
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater Lamp (Export) GY Right Front Fender 39
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Sensor 1
(Premium ORC)DKGY Right B Pillar 39
Right Sliding Door Control
Module C1BK Rear of Door 45, 46
Right Sliding Door Control
Module C2Rear of Door 45, 46
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 45
Right Sliding Door Lock Motor BK Rear of Door 45
Right Sliding Door Lock
Motor/Ajar Switch (Manual Sliding
Door)BK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 45
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
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE NUMBER LOCATION FIG.
S126 In Right Headlamp Leveling Assembly N/S
S127 (Diesel) In T/O for Engine Starter Motor N/S
S128 (Diesel) Near T/O for Engine Starter Motor N/S
S129 (Diesel) Near T/O for Battery (+) N/S
S130 (Diesel) 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 C110 N/S
S132 (Diesel) Near T/O for Battery (+) N/S
S134 (Diesel) IN T/O for Engine Control Module N/S
S135 (Diesel) Near T/O for Glow Plug No.2 N/S
S136 (Diesel) In T/O for Radiator Fan Relays 2
S137 (Diesel) Above Starter 15
S138 (Diesel) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S139 (Diesel) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C115, 16
S141 (2.4L) Near T/O for C110 11
S141 (Diesel) 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
S144 (Diesel) Between T/O for Battery Temperature Sensor and T/O
for C103N/S
S148 (Diesel) Near T/O for Engine Starter Motor 5
S150 (Diesel) Between T/O for Battery Temperature Sensor and T/O
for C103N/S
S151 (Diesel) Near T/O for Radiator Fan Relays 2
S152 (Diesel) Near T/O for Radiator Fan No.1 N/S
S157 (Diesel) Near T/O for Glow Plug No.4 15
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (Diesel) In T/O for Engine Control Module C1 N/S
S188 (Diesel) Near T/O for Radiator Fan Relays 2
S201 In T/O to Instrument Panel Speaker 20, 26
S202 Near T/O for Instrument Panel Switch Bank 20, 26
S203 Near T/O for Instrument Panel Switch Bank 26
S204 Near T/O to Instrument Panel Speaker 20, 26
S205 Near T/O for C201 N/S
S206 Near T/O for Instrument Cluster 20
S207 Near T/O for A/C Heater Control 20, 26
S208 (RHD) Between T/O for Antenna Connector and T/O for Front
Cigar Lighter26
S209 Near T/O for Evaporator Temperature Sensor N/S
S210 (RHD) Near T/O for C203 26
S211 In Steering Column Wiring Assembly N/S
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

8W-97 POWER DISTRIBUTION SYSTEM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........1
INTEGRATED POWER MODULE
DESCRIPTION..........................2
OPERATION............................2
REMOVAL.............................2
INSTALLATION..........................3IOD FUSE
DESCRIPTION..........................3
OPERATION............................3
POWER OUTLET
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 4
REMOVAL.............................5
INSTALLATION..........................5
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.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
Terminal Pick Kit 6680
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1