volt CHRYSLER VOYAGER 2004 Service Manual

POWERTRAIN CONTROL MODULE C2 - BLACK 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 K58 16BR/VT (3.3L/3.8L) INJECTOR CONTROL NO. 6
5 K38 16BR/OR (3.3L/3.8L) INJECTOR CONTROL NO. 5
6- -
7 K18 16BR/OR (3.3L/3.8L) COIL CONTROL NO. 3
8 K35 18DB/VT (3.3L) EGR SOLENOID CONTROL
9 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
10 K19 18DB/DG COIL CONTROL NO. 1
11 K14 16 BR/TN INJECTOR CONTROL NO. 4
12 K13 16BR/LB INJECTOR CONTROL NO. 3
13 K12 16BR/DB INJECTOR CONTROL NO. 2
14 K11 16BR/YL INJECTOR CONTROL NO. 1
15 - -
16 - -
17 - -
18 K99 18BR/LG O2 1/1 HEATER CONTROL
19 K20 18BR/GY GEN FIELD CONTROL
20 K2 18VT/OR ECT SIGNAL
21 K22 18BR/OR TP NO. 1 SIGNAL
22 K34 18DB/LG (3.3L) EGR SOLENOID SIGNAL
23 K1 18VT/BR MAP SIGNAL
24 K942 18BR/LG KS RETURN
25 K42 18DB/YL KNOCK SENSOR NO. 1 SIGNAL
26 - -
27 K900 18DB/DG SENSOR GROUND
28 K961 18BR/VT IAC RETURN
29 F855 20PK/YL 5 VOLT SUPPLY
30 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
31 K41 18DB/LB O2 1/1 SIGNAL
32 K902 18BR/DG O2 RETURN (UP)
33 - -
34 K44 18DB/GY CMP SIGNAL
35 K24 18BR/LB CKP SIGNAL
36 - -
37 - -
38 K61 18VT/GY IAC MOTOR CONTROL
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 111

RADIO C1 - 22 WAY
CAV CIRCUIT FUNCTION
1 A114 16GY/RD FUSED B(+) (I.O.D.)
2 F306 18DB/PK FUSED ACCESSORY RELAY OUTPUT
3 E14 20OR/TN PANEL LAMPS DRIVER
4- -
5- -
6- -
7 X54 20GY (EXCEPT LOWLINE 1) RIGHT FRONT SPEAKER (+)
7 X154 20GY/YL (LOWLINE 1) RIGHT INSTRUMENT PANEL SPEAKER (+)
8 X56 20GY/BR (EXCEPT LOWLINE 1) RIGHT FRONT SPEAKER (-)
8 X156 20GY/LB (LOWLINE 1) RIGHT INSTRUMENT PANEL SPEAKER (-)
9 X55 20DG/BR (EXCEPT LOWLINE 1) LEFT FRONT SPEAKER (-)
9 X155 20DG/LB (LOWLINE 1) LEFT INSTRUMENT PANEL SPEAKER (-)
10 X53 20DG (EXCEPT LOWLINE 1) LEFT FRONT SPEAKER (+)
10 X153 20DG/YL (LOWLINE 1) LEFT INSTRUMENT PANEL SPEAKER (+)
11 Z514 16BK/LG GROUND
12 A114 16GY/RD FUSED B(+) (I.O.D.)
13 X60 20GY/YL RADIO 12 VOLT OUTPUT
14 D25 20WT/VT PCI BUS
15 - -
16 - -
17 - -
18 X51 22DG/DB LEFT REAR SPEAKER (+)
19 X57 22DG/OR LEFT REAR SPEAKER (-)
20 X58 22GY/OR RIGHT REAR SPEAKER (-)
21 X52 22GY/DB RIGHT REAR SPEAKER (+)
22 Z515 16BK GROUND
RADIO C2 (CD CHANGER)-8WAY
CAV CIRCUIT FUNCTION
1 X40 22GY/WT (EXCEPT EXPORT) AUDIO OUT RIGHT
1 X40 20GY/WT (EXPORT) AUDIO OUT RIGHT
2 X140 22GY/OR (EXCEPT EXPORT) COMMON AUDIO
2 Z140 18BK/OR (EXPORT) GROUND
3 X235 20GY/LB (EXCEPT EXPORT) SHIELD
4 D25 20WT/VT (EXCEPT EXPORT) PCI BUS
4 D25 20VT/YL (EXPORT) PCI BUS
5 X112 20DG/GY (EXCEPT EXPORT) IGNITION SWITCH SIGNAL
5 X112 20RD (EXPORT) IGNITION SWITCH SIGNAL
6 X41 22DG/WT (EXCEPT EXPORT) AUDIO OUT LEFT
6 X41 20DG/WT (EXPORT) AUDIO OUT LEFT
7 Z141 20BK/TN (EXCEPT EXPORT) GROUND
7 Z141 18BK/TN (EXPORT) GROUND
8- -
9 E14 22OR/TN (EXCEPT EXPORT) PANEL LAMPS DRIVER
9 E14 18OR/TN (EXPORT) PANEL LAMPS DRIVER
10 X160 20GY/YL FUSED B(+)
8W - 80 - 116 8W-80 CONNECTOR PIN-OUTSRS

REAR BLOWER REAR CONTROL SWITCH C2 (3 ZONE MTC) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1- -
2 C22 20LB/DB REAR TEMPERATURE FEEDBACK SIGNAL
3 E10 20OR/DG PANEL LAMPS DRIVER
4 F850 20LB/PK 5 VOLT SUPPLY
5 C121 20DB/DG REAR TEMPERATURE RETURN
6 Z409 20BK/OR GROUND
REAR DOME LAMP (EXCEPT LUXURY) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 M22 20YL/OR COURTESY LAMPS DRIVER
2 Z327 20BK/OR GROUND
3- -
REAR INTRUSION SENSOR (UNITED KINGDOM)-3WAY
CAV CIRCUIT FUNCTION
1 A645 20RD/VT REAR INTRUSION SENSOR SIGNAL
2- -
3 G945 20VT/DG SENSOR GROUND
REAR MODE MOTOR (3 ZONE ATC) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C154 18LB/GY REAR MODE DOOR DRIVER (B)
2 C53 18LB REAR MODE DOOR DRIVER (A)
REAR POWER OUTLET - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 F307 18LB/PK (ACCESSORY RELAY
POSITION)FUSED ACCESSORY RELAY OUTPUT
1 F307 18LB/PK (BATTERY POSITION) FUSED B(+)
2- -
3 Z737 18BK/LB GROUND
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 119

RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
2 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
3 Z378 18BK/TN GROUND
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
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 123

RIGHT REAR SPEAKER (LOWLINE)-3WAY
CAV CIRCUIT FUNCTION
1 X58 20GY/OR RIGHT REAR SPEAKER (-)
2- -
3 X52 20GY/DB RIGHT REAR SPEAKER (+)
RIGHT REAR VENT MOTOR - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1- -
2 Q14 16OR/BR (LHD EXCEPT EXPORT) PASSENGER SIDE REAR WINDOW CLOSE
2 Q14 16OR/BR (LHD EXPORT) PASSENGER SIDE REAR WINDOW CLOSE
2 Q13 16OR/DB (RHD) DRIVER SIDE REAR WINDOW CLOSE
3 Q24 16OR/DG (LHD) PASSENGER SIDE REAR WINDOW OPEN
3 Q23 16OR/LB (RHD) DRIVER SIDE REAR WINDOW OPEN
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X10 22RD/DB RADIO CONTROL MUX
2 X20 22RD/BK RADIO CONTROL MUX RETURN
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 127

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

INTEGRATED POWER MODULE
DESCRIPTION
The Integrated Power Module (IPM) is a combina-
tion of the Power Distribution Center (PDC) and the
Front Control Module (FCM). The IPM is located in
the engine compartment, next to the battery on this
model (Fig. 1). The power distribution center mates
directly with the Front Control Module (FCM) to
form the IPM Fuse and Relay Center. The power dis-
tribution center (PDC) is a printed circuit board
based module that contains fuses and relays, while
the front control module contains the electronics con-
trolling the IPM and other functions. This IPM con-
nects directly to the battery positive via a four pin
connector. The ground connection is via two other
connectors. The IPM provides the primary means of
voltage distribution and protection for the entire
vehicle.
The molded plastic IPM housing includes a base
and cover. The IPM cover is easily opened or removed
for service access by squeezing the two marked cover
latches and has a fuse and relay layout map integral
to the inside surface of the cover. This IPM housing
base and cover are secured in place by an IPM
mounting bracket. This mounting bracket is designed
to allow the IPM to rotate counter-clockwise once the
locking tab is disengaged. The IPM mounting bracketis secured in place by bolts threaded into the left
front wheel house.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) via a four- pin connector on the bottom of the
module. The IPM cover is unlatched and opened or
removed to access the fuses or relays. Internal con-
nections of all of the power distribution center cir-
cuits is accomplished by a combination of bus bars
and a printed circuit board. Refer to the Wiring sec-
tion of the service manual for complete IPM circuit
schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard from the
vehicle. Refer to the Battery section for the proce-
dure.
(3) Remove the battery from the vehicle. Refer to
the Battery section for the procedure.
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 2).
(5) Rotate the IPM counter-clockwise to access and
disconnect the various electrical connectors (Fig. 3).
(6) Free the IPM from its mounting bracket by
removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.
Fig. 1 BATTERY THERMAL GUARD
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
Fig. 2 RELEASING INTEGRATED POWER MODULE
FROM ITS MOUNTING BRACKET
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS

POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3) Open the power outlet door. Check for continu-
ity between the inside circumference of the power
outlet receptacle and a good ground. There should be
continuity. If OK, go to Step 4. If not OK, go to Step
5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 4).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 5).(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 4 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 5 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
POWER OUTLET (Continued)