ignition 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

POWERTRAIN CONTROL MODULE C3 - BLACK 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 K51 18BR/WT ASD RELAY CONTROL
4- -
5 V35 18VT/OR S/C VENT CONTROL
6 K173 18BR/VT CONDENSER FAN RELAY CONTROL
7 V32 18VT/YL SPEED CONTROL SUPPLY
8 K106 20VT/LB (EXCEPT EXPORT) NVLD SOL CONTROL
9 K299 18BR/WT O2 1/2 HEATER CONTROL
10 - -
11 C13 18LB/OR A/C CLUTCH RELAY CONTROL
12 V36 18VT/YL S/C VACUUM CONTROL
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 K342 16BR/WT ASD RELAY OUTPUT
20 K52 18DB/WT EVAP PURGE CONTROL
21 T141 18YL (MTX EXPORT) FUSED IGNITION SWITCH OUTPUT (START)
22 - -
23 B29 18DG/WT BRAKE SWITCH SIGNAL
24 - -
25 - -
26 - -
27 - -
28 K342 16BR/WT ASD RELAY OUTPUT
29 K70 18DB/BR EVAP PURGE SIGNAL
30 - -
31 C18 18LB/BR A/C PRESSURE SIGNAL
32 K91 18DB/YL BATTERY TEMP SIGNAL
33 - -
34 V37 18VT S/C SWITCH NO. 1 SIGNAL
35 K107 20VT/WT (EXCEPT EXPORT) NVLD SWITCH SIGNAL
36 - -
37 K31 18BR FUEL PUMP RELAY CONTROL
38 T752 18DG/OR STARTER RELAY CONTROL
8W - 80 - 112 8W-80 CONNECTOR PIN-OUTSRS

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

RADIO C2 (DVD/CD CHANGER) - DK. GRAY 10 WAY
CAV CIRCUIT FUNCTION
1 X40 22GY/WT AUDIO OUT RIGHT
2 X140 22GY/OR COMMON AUDIO
3 X235 20GY/LB SHIELD
4 D25 20WT/VT PCI BUS
5 X112 20DG/GY IGNITION SWITCH SIGNAL
6 X41 22DG/WT AUDIO OUT LEFT
7- -
8- -
9 E14 22OR/TN PANEL LAMPS DRIVER
10 - -
REAR A/C-HEATER UNIT (3 ZONE MTC) - LT. GREEN 10 WAY
CAV CIRCUIT FUNCTION
1 C53 20LB REAR MODE DOOR DRIVER
2 C154 20LB/OR REAR COMMON DOOR DRIVER
3 C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
4 C152 16LB/LG REAR BLOWER MOTOR MED
5 C151 18LB/DG REAR BLOWER MOTOR LOW
6 C153 12DB/OR REAR BLOWER MOTOR HIGH
7 C54 20LB/YL REAR BLEND DOOR DRIVER
8 C154 20LB/OR REAR COMMON DOOR DRIVER
9- -
10 - -
REAR AUTO TEMP CONTROL SWITCH (3 ZONE ATC) - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z27 18BK/DG GROUND
3 D22 22WT/TN KDB CLOCK
4 D17 22WT/DG KDB DATA
5 E10 20OR/DG PANEL LAMPS DRIVER
6- -
7- -
8- -
9- -
10 - -
11 - -
12 - -
13 - -
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 117

RIGHT VISOR/VANITY LAMP (PREMIUM/LUXURY EXCEPT EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMPS DRIVER
SENTRY KEY REMOTE ENTRY MODULE (SKREEM) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 D10 18WT (RHD) REMOTE KEYLESS ENTRY ANTENNA (+)
2 D25 20WT/VT PCI BUS
3 D10 18WT/LB (RHD) REMOTE KEYLESS ENTRY ANTENNA (-)
4 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z120 22BK/WT GROUND
6 A114 20GY/RD FUSED B(+) (I.O.D.)
SIREN (UNITED KINGDOM) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 D96 18WT/LB SIREN SIGNAL CONTROL
3 A114 18GY/RD FUSED B(+) (I.O.D.)
4 Z109 18BK/GY GROUND
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18VT/YL S/C VACUUM CONTROL
2 V35 18VT/OR S/C VENT CONTROL
3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT
4 Z155 18BK/LG GROUND
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 131

SUNROOF MODULE (EXCEPT EXPORT) - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 Q3 20OR/TN SUNROOF VENT
2 Q5 20OR/LB SUNROOF CLOSE
3 Q4 20OR/YL SUNROOF OPEN
4 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
5 A115 14YL/RD FUSED B(+)
6 Z138 14BK/DB GROUND
7- -
8- -
9- -
10 - -
11 - -
12 - -
SUNROOF SWITCH (EXCEPT EXPORT) - NATURAL 4 WAY
CAV CIRCUIT FUNCTION
1 Q3 20OR/TN SUNROOF VENT
2 Q4 20OR/YL SUNROOF OPEN
3 Z137 20BK/DB GROUND
4 Q5 20OR/LB SUNROOF CLOSE
THATCHAM ALARM MODULE (UNITED KINGDOM) - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 A645 20RD/VT REAR INTRUSION SENSOR SIGNAL
2 G460 20DG/VT FRONT INTRUSION SENSOR SIGNAL
3 G22 20YL VTSS INDICATOR SUPPLY
4 D23 20WT/BR FLASH PROGRAM ENABLE
5- -
6 D96 20WT/LB SIREN SIGNAL CONTROL
7 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 Z109 20BK/GY GROUND
9 G945 20VT/DG SENSOR GROUND
10 G946 20LG/VT SENSOR GROUND
11 G922 20GY VTSS INDICATOR DRIVER
12 - -
13 D25 20WT/VT PCI BUS
14 - -
15 L91 20WT/DB HAZARD SWITCH SENSE
16 A114 18GY/RD FUSED B(+) (I.O.D.)
8W - 80 - 132 8W-80 CONNECTOR PIN-OUTSRS

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

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Ignition Coil (2.4L) BK Top of Valve Cover 10, 11
Ignition Coil (3.3L/ 3.8L) DKGY Top of Engine 17, 18
Ignition Switch BK Rear of Switch at Steering Column 20, 21, 22, 23, 31
Inlet Air Temperature Sensor BK Top Left of Engine 9, 10, 11, 17
Input Speed Sensor GY Front of Transmission 14, 19
Instrument Cluster BK Rear of Cluster 20, 21, 28
Instrument Panel Switch Bank
(Heated Seats)BK Right Center of Instrument Panel 20, 23, 25
Instrument Panel Switch Bank
(Except Heated Seats)Right Center of Instrument Panel 20, 23, 25
Integrated Power Module C1 Left Fender Shield 6, 7
Integrated Power Module C2 GN/BL Left Fender Shield 6, 7
Integrated Power Module C3 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 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 (2.4L) BK At Engine Block N/S
Knock Sensor (3.3L/3.8L ABS
Except Export)GY Front of Cylinder Block 11
Left B Pillar Switch (Power
Sliding Door)GY Left B Pillar 40
Left Cinch/Release Motor (Power
Sliding Door)GY Left Sliding Door N/S
Left Cylinder Lock Switch BK At Switch 43
Left Door Speaker (Highline) BK/RD At Speaker 43
Left Door Speaker (Lowline) In Door N/S
Left Fog Lamp (Except Export) BK At Lamp N/S
Left Fog Lamp (Export) WT At Lamp 5
Left Front Door Ajar Switch
(Base)BK At Switch N/S
Left Front Door Lock Motor/Ajar
Switch (Except Base)BK Left Door 43
Left Front Impact Sensor (Except
Export)BK Near T/O for C300 N/S
Left Front Park/Turn Signal Lamp
(Except Export)DKGY At Lamp 1
Left Front Wheel Speed Sensor GY Left Fender Side Shield 5, 11
Left Full Open Switch (Power
Sliding Door)BK Left Sliding Door N/S
Left Headlamp (Except Export) BK At Lamp 1
Left Headlamp Leveling Motor
(Export)WT At Motor N/S
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

INSTALLATION
(1) Snap the left side of the Integrated Power Mod-
ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors. Care must be
taken that the Connector Positive Assurance (CPA)
on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).
NOTE: IPM electrical connectors are color coded to
ease location reference.
(2) Being certain no wires are stressed or pinched,
rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.
(3) Install the battery in the vehicle. Refer to the
Battery section for the procedure.
(4) Install the battery thermal guard in the vehi-
cle. Refer to the Battery section for the procedure.
(5)
Connect the negative and positive battery cables.
(6) Using a diagnostic scan tool, check for any
stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) whenthe vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.
The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
tion. The IOD fuse is a 20 ampere blade-type mini
fuse and, when removed, it is stored in a fuse cavity
adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal condi-
tion where power is being drained from the battery with
the ignition switch in the Off position. The IOD fuse
feeds the memory and sleep mode functions for some of
the electronic modules in the vehicle as well as various
other accessories that require battery current when the
ignition switch is in the Off position, including the
clock. The only reason the IOD fuse is removed is to
reduce the normal IOD of the vehicle electrical system
during new vehicle transportation and pre-delivery stor-
age to reduce battery depletion, while still allowing
vehicle operation so that the vehicle can be loaded,
unloaded and moved as needed by both vehicle trans-
portation company and dealer personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
Fig. 3 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-3
INTEGRATED POWER MODULE (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)