battery CHRYSLER VOYAGER 2005 Service Manual

EGR SOLENOID (3.3L) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 K34 18DB/LG EGR SOLENOID SIGNAL
2 F855 18PK/YL 5 VOLT SUPPLY
3 K900 18DB/DG SENSOR GROUND
4 Z335 18BK/DB GROUND
5- -
6 K35 18DB/VT EGR SOLENOID CONTROL
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K35 20GY/YL EGR SOLENOID CONTROL
2 K342 16BR/WT ECM/PCM RELAY OUTPUT
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
1 Z130 14BK/BR GROUND
2 Z131 14BK/DG GROUND
3 K20 14BR/GY GENERATOR FIELD CONTROL
4 K342 14BR/WT ECM/PCM RELAY OUTPUT
5 K342 14BR/WT ECM/PCM RELAY OUTPUT
6- -
7 D25 20WT/VT PCI BUS
8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND
9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
NO. 1
16 K80 20DB/TN FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 K342 20BR/WT ECM/PCM RELAY OUTPUT
20 Z138 20BK/OR GROUND
21 K900 20DB/DG SENSOR GROUND
22 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B
24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
25 - -
26 - -
27 - -
28 - -
29 - -
30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL
32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL
8W - 80 - 66 8W-80 CONNECTOR PIN-OUTSRS

EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K52 18DB/WT EVAP PURGE CONTROL
2 K70 18DB/BR EVAP PURGE RETURN
EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 C121 20DB/DG SENSOR GROUND
FLOOR CONSOLE LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 M27 18OR (FRONT POSITION) READING LAMPS DRIVER
1 F307 18OR (REAR POSITION/ACCES-
SORY RELAY POSITION)FUSED ACCESSORY RELAY OUTPUT
1 F307 18OR (REAR POSITION/BATTERY
POSITION)FUSED B(+)
2 Z746 16BK (FRONT POSITION) GROUND
2 Z747 16BK (REAR POSITION) GROUND
FLOOR CONSOLE POWER OUTLET (EXPORT) - RED 3 WAY
CAV CIRCUIT FUNCTION
1 A105 16RD (FRONT POSITION) FUSED B(+)
1 F307 16RD (REAR POSITION/ACCES-
SORY RELAY POSITION)FUSED ACCESSORY RELAY OUTPUT
1 F307 16RD (REAR POSITION/BATTERY
POSITION)FUSED B(+)
2- -
3 Z746 16BK (FRONT POSITION) GROUND
3 Z747 16BK (REAR POSITION) GROUND
8W - 80 - 70 8W-80 CONNECTOR PIN-OUTSRS

INTEGRATED POWER MODULE C5 - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 A1 4RD B(+)
2- -
3- -
4- -
INTEGRATED POWER MODULE C6 - NATURAL 10 WAY
CAV CIRCUIT FUNCTION
1 A101 12VT/RD FUSED B(+)
2 Z117 16BK/WT GROUND
3 Z118 16BK/WT (LWB/EXPORT) GROUND
3 Z118 16BK/YL (SWB/EXCEPT EXPORT) GROUND
4 A110 12OR/RD (POWER SEAT) FUSED B(+)
5- -
6- -
7 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT
8 F307 18LB/PK (ACCESSORY RELAY
POSITION)FUSED ACCESSORY RELAY OUTPUT
8 F307 18LB/PK (BATTERY POSITION) FUSED B(+)
9 A113 12WT/RD (POWER SLIDING
DOOR)FUSED B(+)
10 - -
INTEGRATED POWER MODULE C7 - 20 WAY
CAV CIRCUIT FUNCTION
1 C16 20DB/GY FUSED DEFOGGER RELAY OUTPUT
2 T141 20YL/OR (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
2 T751 20YL (GAS) FUSED IGNITION SWITCH OUTPUT (START)
3 D25 20WT/VT PCI BUS
4 L13 20WT/YL (EXPORT) HEADLAMP ADJUST SIGNAL
5 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
6- -
7 W7 20BR/GY WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
9 F201 20PK/OR ORC RUN-START DRIVER
10 - -
11 A106 20LB/RD FUSED B(+)
12 P201 20LG/DB (EXCEPT EXPORT/EX-
CEPT MEMORY)ADJUSTABLE PEDALS RELAY CONTROL
13 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
14 - -
15 A114 16GY/RD FUSED B(+) (I.O.D.)
16 D123 20WT/BR FLASH PROGRAM ENABLE
17 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
17 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT
18 - -
19 X3 20DG/VT HORN SWITCH SENSE
20 F100 18PK/VT ORC RUN ONLY DRIVER
8W - 80 - 84 8W-80 CONNECTOR PIN-OUTSRS

POWERTRAIN CONTROL MODULE C3 - NATURAL 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 RAD 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 - 118 8W-80 CONNECTOR PIN-OUTSRS

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
8W - 80 - 126 8W-80 CONNECTOR PIN-OUTSRS

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 Pressure Sensor GY At Throttle Body 9, 10, 15, 16, 17
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
Accelerator Pedal Position
Sensor (Diesel)At Accelerator Pedal 42
Adjustable Pedals Module
(Except Export)Near Brake Lamp Switch N/S
Adjustable Pedals Motor On Pedal Support N/S
Adjustable Pedals Relay (Except
Export)Left Side Engine Compartment 6
Adjustable Pedals Sensor On Adjustable Pedals Motor N/S
Adjustable Pedals Switch (Except
Export)Left Side Kick Panel 41
Ambient Temperature Sensor
(Except Base)BK On Radiator Closure Panel 1
Amplifier C1 NAT Right Quarter Panel 48
Amplifier C2 NAT Right Quarter Panel 48
ATC Remote Sensor Above ATC Control N/S
Auto Temp Control C1 NAT Rear of Control 20
Auto Temp Control C2 BK Rear of Control 20
Auto Temp Control C3 (MTX) Rear of Control N/S
Back-Up Lamp Switch BK On Transmission 16
Battery Temperature Sensor BK At Battery N/S
Blower Motor Resistor C1 (MTC) BK Right Side of HVAC N/S
Blower Motor Resistor C2 (MTC) BK Right Side of HVAC N/S
Body Control Module C1 BK Under Left Instrument Panel 41, 42
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-1

SPLICES
SPLICE NUMBER LOCATION FIG.
S101 (Gas) Near T/O for Radiator Fan No.1 1
S103 (Diesel) Between T/O for Battery Temperature Sensor and T/O
for C10215
S106 (2.5L) Near T/O for Battery Temperature Sensor 15
S106 (3.3L/3.8L) Near T/O for G103 18
S107 (Gas) Near T/O for Integrated Power Module C3 11
S107 (Diesel) In T/O for Integrated Power Module C3 7
S111 (2.4L) Near T/O for C101 11
S111 (Diesel) In T/O for Battery (-) N/S
S111 (3.3L/3.8L) Near T/O for Battery Temperature Sensor N/S
S112 (Gas) Near T/O for Integrated Power Module - C3 19, 5, 11
S113 (2.4L) Near T/O for Park/Neutral Position Switch 11
S114 (2.4L) Near T/O for Powertrain Control Module C4 11
S114 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S115 (2.4L) Near T/O for Powertrain Control Module C4 11
S115 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S116 (2.4L) 180mm from T/O for Torque Converter Clutch Solenoid 11, 13
S116 (Diesel) Near T/O for Mass Air Flow Sensor 16
S116 (3.3L/3.8L) Near T/O for G103 18
S118 (2.4L) Near T/O for Knock Sensor 11, 13
S119 (Diesel) Near T/O for Engine Starter Motor 15
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 18
S122 (2.4L) In T/O to Engine Starter Motor 13
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 18
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
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 (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 (2.4L) 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
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE NUMBER LOCATION FIG.
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 Controller Anti-Lock Brake 11
S141 (3.3L/3.8L ABS Except
Export)Near T/O for G100 N/S
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) Near T/O for Controller Anti-Lock Brake N/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 15
S188 (Diesel) Near T/O for Radiator Fan Relays 2
S189 (Diesel EATX) Near T/O for Battery (+) N/S
S190 (Diesel EATX) Near T/O for Transmission Control Module N/S
S191 (Diesel EATX) Near T/O for Transmission Control Module N/S
S192 (Diesel EATX) In T/O for Transmission Control Module N/S
S193 (Diesel EATX) In T/O for Transmission Control Module N/S
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 20, 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
S212 In Steering Column Wiring Assembly N/S
S222 Near T/O for C204 N/S
S223 Near T/O for Multi-Function Switch 20
S224 Near T/O for Siren N/S
S225 (Hands Free) Near T/O for Rear View Mirror N/S
S226 (Hands Free) In T/O for C207 N/S
S302 In Floor Pan Track Wiring 37
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..........................1
OPERATION............................2
REMOVAL.............................2
INSTALLATION..........................2IOD FUSE
DESCRIPTION..........................3
OPERATION............................3
POWER OUTLET
DESCRIPTION..........................3
OPERATION............................3
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 3
REMOVAL.............................4
INSTALLATION..........................4
POWER DISTRIBUTION
SYSTEM
DESCRIPTION
The power distribution system for this vehicle con-
sists 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
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 theelectrical current needed to operate many accessories
that the vehicle owner may choose to have installed.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
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. (Fig. 1).
The PDC mates directly with the FCM to form the
IPM. The PDC is a printed circuit board based mod-
ule that contains fuses and relays, while the FCM
contains the electronics controlling the IPM and
other functions. This IPM connects directly to the
battery positive through a four pin connector. The
ground connection is through two other connectors.
Terminal Pick Kit 6680
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1

The IPM provides the primary means of voltage dis-
tribution and protection for the entire vehicle.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) through a four- pin connector on the bottom of
the module. Internal connections of all of the power
distribution center circuits is accomplished by a com-
bination of bus bars and a printed circuit board.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard.
(3) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the IPM from its mounting bracket
(Fig. 2).
(5) Rotate the IPM counter-clockwise to access and
disconnect the electrical connectors (Fig. 3).
(6) Remove the IPM bracket clips from the hinge.
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.NOTE: Ensure that the Connector Positive Assur-
ance (CPA) on the five-pin B+ connector is posi-
tively engaged to prevent generating a Diagnostic
Trouble Code (DTC).
(2) Rotate the IPM clock-wise until secured in
mounting bracket. An audible click may be heard.
(3) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(4) Install the battery thermal guard.
Fig. 1 INTEGRATED POWER MODULE
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
Fig. 2 INTEGRATED POWER MODULE
Fig. 3 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
INTEGRATED POWER MODULE (Continued)