1996 CHRYSLER VOYAGER service

(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 10)
(6) Twist the wires together (example 3) (Fig. 10)
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation
(10) Connect battery and test all affected systems.
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 11).
(4) Using special tool 6742 release the locking fin-
gers on the terminal (Fig. 12).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal, as
necessary.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component(3) Remove the connector locking wedge, if
required (Fig. 13)
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
Fig. 10 Wire Repair
Fig. 11 Molex Connector Repair
Fig. 12 Using Special Tool 6742
Fig. 13 Connector Locking Wedge
NS/GS8W-01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)

kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 14) (Fig. 15).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9)
Connect connector to its mating half/component.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at
1/2 inch intervals (Fig. 16).(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 16).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push down on the yellow connector locking tab
to release the terminals (Fig. 17).
(4) Using special tool 6932, push the terminal to
remove it from the connector (Fig. 18).
Fig. 14 Terminal Removal
Fig. 15 Terminal Removal Using Special Tool
Fig. 16 Stagger Cutting Wires
8W - 01 - 12 8W-01 GENERAL INFORMATIONNS/GS
SERVICE PROCEDURES (Continued)

(5) Repair or replace the connector or terminal as
necessary.
(6) When re-assembling the connector, the locking
wedge must be placed in the locked position to pre-
vent terminal push out.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 19).
(3) Remove connector locking wedge, if required
(Fig. 19).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 20) (Fig. 21).
(5) Cut the wire 6 inches from the back of the con-
nector.
(6) Remove 1 inch of insulation from the wire on
the harness side.(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
Fig. 17 Augat Connector Repair
Fig. 18 Using Special Tool 6932
Fig. 19 Connector Locking Wedge Tab (Typical)
Fig. 20 Terminal Removal
Fig. 21 Terminal Removal Using Special Tool
NS/GS8W-01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)

(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires.
(11) Push the two ends of wire together until the
strands of wire are close to the insulation.
(12) Twist the wires together.
(13) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect battery, and test all affected systems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8)
Re-connect the battery, and test affected systems.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 22 Diode Identification
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
8W - 01 - 14 8W-01 GENERAL INFORMATIONNS/GS
SERVICE PROCEDURES (Continued)

Component Page
Seat Belt Indicator Lamp.................8W-40
Seat Belt Switch........................8W-40
Sentry Key Immobilizer Module............8W-39
Service Engine Soon Lamp.............8W-30, 46
Sliding Door Contacts....................8W-61
Sliding Door Lock Motors.................8W-61
Speed Control Switches...............8W-30, 33
Speedometer...........................8W-40
Stop Lamp Switch...................8W-33, 51
Stop/Turn Signal Relays..................8W-54
Tachometer............................8W-40
Tail/Stop Lamp.........................8W-51
Tail/Turn Signal Lamp................8W-51, 52
Throttle Position Sensor..................8W-30
Traction Control Switch..................8W-35
Trailer Tow Connector...................8W-54
Transmission Control Module..............8W-31
Transmission Control Relay............8W-10, 31
Transmission Control Solenoids............8W-31
Transmission Range Sensor...............8W-31
Trip Odometer.........................8W-40Component Page
Turbine Speed Sensor....................8W-31
Turbo Boost Pressure Sensor..............8W-30
Turn Indicators......................8W-46, 52
Turn Signal/Hazard Switch............8W-46, 52
Underdrive Solenoid.....................8W-31
Universal Garage Door Opener............8W-49
Vacuum Solenoid.......................8W-33
Vehicle Speed Control Servo...............8W-33
Vehicle Speed Sensor....................8W-30
Vent Motors...........................8W-60
Vent Solenoids.........................8W-33
Visor/Vanity Mirror Lamps................8W-44
Voltage Regulator.......................8W-20
Volts Indicator Lamp....................8W-40
VTSS Lamp........................8W-39, 46
Washer Module.........................8W-53
Wheel Speed Sensors....................8W-35
Wiper High/Low Relay...................8W-53
Wiper Module..........................8W-53
Wiper On Relay........................8W-53
NS/GS8W - 02 COMPONENT INDEX 8W - 02 - 3

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay................8W-30-5, 37
A/C Heater Control....................8W-30-5, 32, 37
A/C Pressure Transducer.............8W-30-10, 16, 24, 38
Accelerator Pedal Position Sensor...............8W-30-38
Airbag Control Module....................8W-30-4, 31
All Wheel Drive Solenoid....................8W-30-20
Automatic Shut Down Relay . . .8W-30-2, 7, 8, 9, 14, 15, 21, 22, 23
AW4B13...............................8W-30-6
AW4B13..............................8W-30-20
AWS1................................8W-30-20
AWS2................................8W-30-20
Back-Up Switch........................8W-30-6, 20
Battery..........................8W-30-2, 3, 29, 32
Body Control Module.............8W-30-4, 6, 20, 31, 36, 39
BS01................................8W-30-39
BS02...............................8W-30-6, 20
BS05...............................8W-30-4, 31
BS06...............................8W-30-4, 31
BS30................................8W-30-36
BS31..............................8W-30-28, 35
BS32................................8W-30-33
BS33................................8W-30-28
BS34..........................8W-30-33, 34, 36, 38
BS40................................8W-30-35
BS41................................8W-30-35
Camshaft Position Sensor..............8W-30-8, 14, 22, 24
Clockspring...........................8W-30-5, 39
Clutch Switch...........................8W-30-39
Compass/Mini-Trip Computer.................8W-30-31
Control Sleeve Sensor......................8W-30-34
Controller Anti-Lock Brake.................8W-30-4, 31
Crank Case Heater........................8W-30-29
Crankshaft Position Sensor...............8W-30-8, 14, 22
Data Link Connector.................8W-30-3, 4, 30, 31
Diesel Power Relay.................8W-30-28, 29, 32, 33
Downstream Heated Oxygen Sensor............8W-30-7, 21
EGR Solenoid.......................8W-30-18, 20, 29
Engine Coolant Temperature Sensor......8W-30-10, 16, 24, 36
Engine Speed Sensor.......................8W-30-35
Engine Starter Motor Relay...............8W-30-6, 20, 28
ES01................................8W-30-29
ES02.............8W-30-8, 10, 11, 14, 16, 17, 22, 24, 25, 29
ES03.....................8W-30-10, 11, 16, 17, 24, 25
ES05...................8W-30-14, 19, 22, 25, 33, 34, 36
ES06..........................8W-30-28, 29, 32, 33
ES07..........................8W-30-2, 18, 20, 26
ES08............................8W-30-17, 19, 25
ES09................................8W-30-37
ES11................................8W-30-2, 3
ES12.................8W-30-2, 7, 8, 9, 14, 15, 21, 22, 23
ES13.................................8W-30-4
ES14.................................8W-30-4
ES17........................8W-30-8, 11, 14, 17, 22
ES18...............................8W-30-7, 21
ES21..................8W-30-7, 8, 10, 11, 14, 16, 17, 24
ES24.................................8W-30-3
ES26................................8W-30-32
ES28................................8W-30-32
ES29................................8W-30-32
ES30................................8W-30-35
ES31................................8W-30-35
ES37................................8W-30-32
ES40................................8W-30-29
ES99.................................8W-30-9
Evap Leak Detection Pump................8W-30-18, 26
Evap/Purge Solenoid..................8W-30-12, 18, 26
Flexible Fuel Sensor.......................8W-30-22
FS01..............................8W-30-16, 23
FS02............................8W-30-16, 22, 24
FS03.................................8W-30-15
Fuel Heater............................8W-30-29
Fuel Heater Relay........................8W-30-29
Fuel Injector No. 1....................8W-30-9, 15, 23
Fuel Injector No. 2....................8W-30-9, 15, 23
Fuel Injector No. 3....................8W-30-9, 15, 23
Fuel Injector No. 4....................8W-30-9, 15, 23
Fuel Injector No. 5........................8W-30-23Component Page
Fuel Injector No. 6........................8W-30-23
Fuel Pump Module......................8W-30-33, 34
Fuel Pump Relay.......................8W-30-6, 20
Fuel Quantity Actuator.....................8W-30-33
Fuel Shutdown Solenoid.....................8W-30-33
Fuel Tank Module.......................8W-30-6, 20
Fuel Temperature Sensor....................8W-30-33
Fuel Timing Solenoid......................8W-30-33
Fuse 6 (JB).............................8W-30-32
Fuse 13 (PDC)...........................8W-30-39
Fuse 16 (PDC).....................8W-30-2, 6, 20, 29
Fuse 17 (PDC) . .8W-30-2, 7, 8, 9, 14, 15, 21, 22, 23, 28, 29, 32, 33
Fuse 28 (PDC).........................8W-30-3, 30
Fusible Link A0..........................8W-30-32
G100.............................8W-30-2, 3, 29
G101...............................8W-30-7, 21
G103.............................8W-30-2, 3, 29
G200.............................8W-30-3, 5, 30
G300.................8W-30-7, 13, 19, 21, 27, 28, 35, 39
G301..............................8W-30-30, 35
G302...............................8W-30-6, 20
Generator.......................8W-30-2, 13, 19, 27
Glow Plug Lamp.........................8W-30-32
Glow Plug No. 1..........................8W-30-32
Glow Plug No. 2..........................8W-30-32
Glow Plug No. 3..........................8W-30-32
Glow Plug No. 4..........................8W-30-32
Glow Plug Relay.........................8W-30-32
Idle Air Control Motor.................8W-30-12, 18, 26
Ignition Coil Pack.....................8W-30-8, 14, 22
Instrument Cluster......................8W-30-4, 31
Intake Air Temperature Sensor................8W-30-17
Intake Air Temperature/Manifold Absolute
Pressure Sensor.......................8W-30-10
Junction Block............8W-30-2, 3, 6, 13, 18, 19, 20, 26,
27, 28, 29, 30, 32, 36
Knock Sensor.......................8W-30-10, 16, 24
Left Front Park/Turn Signal Lamp..............8W-30-39
Left Headlamp Leveling Motor.................8W-30-39
Left Speed Control Switch..................8W-30-5, 39
Manifold Absolute Pressure Sensor............8W-30-16, 24
Memory Seat/Mirror Module................8W-30-3, 30
Message Center...................8W-30-13, 19, 27, 32
Needle Movement Sensor....................8W-30-35
Overhead Console.......................8W-30-4, 31
Power Distribution Center .8W-30-2, 3, 5, 6, 7, 8, 9, 14, 15, 18, 20,
21, 22, 23, 26, 28, 29, 30, 32, 33, 36, 37, 39
Powertrain Control Module...................8W-30-10
Powertrain Control Module...................8W-30-11
Powertrain Control Module...................8W-30-12
Powertrain Control Module...................8W-30-13
Powertrain Control Module...................8W-30-8
Powertrain Control Module...................8W-30-9
Powertrain Control Module .8W-30-2, 3, 4, 5, 6, 7, 8, 9, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25, 26,
27, 28, 29, 30, 32, 33, 34, 35, 36, 37, 38, 39
PS01...............................8W-30-4, 31
PS02...............................8W-30-4, 31
PTC 1 (JB)..............8W-30-2, 6, 18, 20, 26, 28, 29, 36
Radiator Fan Relay........................8W-30-5
Radiator Fan Relay No. 1....................8W-30-37
Radiator Fan Relay No. 2....................8W-30-37
Radiator Fan Relay No. 3....................8W-30-37
Radio.............................8W-30-3, 4, 30
Right Speed Control Switch.................8W-30-5, 39
Sentry Key Immobilizer Module.................8W-30-4
Service Engine Soon Lamp..............8W-30-13, 19, 27
Stop Lamp Switch.................8W-30-13, 19, 27, 39
Throttle Position Sensor................8W-30-11, 17, 25
Transmission Control Module.......8W-30-3, 4, 17, 19, 25, 27
Transmission Range Sensor..........8W-30-6, 19, 20, 27, 34
Turbo Boost Pressure Sensor..................8W-30-34
Upstream Heated Oxygen Sensor.............8W-30-7, 21
Vacuum Solenoid.........................8W-30-27
Vehicle Speed Control Servo..............8W-30-13, 19, 27
Vehicle Speed Sensor..................8W-30-11, 17, 36
Vent Solenoid...........................8W-30-27
NS/GS8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1

POWERTRAIN
CONTROL
MODULE
SERVO CONTROL
SPEED
VEHICLE
13
4
STOP
LAMP
SWITCH
V30
18
DB/RD
213
C280
VENT
SOLENOID SOLENOIDVACUUM
56C2
V35
18
LG/RD
TN/RD18 V36
3E43
B707
E43 B706 YL/RD18 V32
5C1C262
K29
18
WT/PK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL CONTROL SOLENOIDVENT CONTROLSPEED
WT/PK20 K29 V32
20
YL/RD STOP LAMP
SWITCH
SENSESPEED
CONTROL
ON/OFF
SWITCH SENSE
2
6
G300
BK20Z1
DB/RD20 V30
K20
18
DG
8C1
2
GENERATOR
7
ST-RUN V23
CENTER MESSAGESERVICE
ENGINE
SOON
LAMP
C1225
B70
E43
P34
B232
A2G3
20
BK/PK
BK/PK20 G3
BK/PK18 G3
LAMP DRIVER SOON INDICATORENGINESEVICE
DRIVERFIELD GENERATOR *13
* RHD RHD LHD
JUNCTION
BLOCK
TOZ1
20
BK
GENERATOR
FIELD
DRIVER
(8W-33-3) (8W-33-3)
(8W-15-7)(8W-20-2) (8W-12-9)
(8W-46-3)
(8W-12-19)
NS/GS8W-30 FUEL/IGNITION SYSTEM
2.0L8W - 30 - 13
GS003013J988W-3

POWERTRAIN
CONTROL
MODULE C1
35
K22
18
OR/DB
OR/DB18 K22
ES08MODULE CONTROL
TRANSMISSION
12
SIGNAL SENSOR POSITION THROTTLE THROTTLE
POSITION
SENSOR
SIGNAL SIGNAL SENSOR POSITION CRANKSHAFT
CRANKSHAFT
POSITION
SENSOR
SIGNAL
6
ES05
K24
18
GY/BK GY/BK18 K24
32C1
BK/YL18 T41
76C2
10
P/N
TRANSMISSION
RANGE
SENSOR
SERVO CONTROL
SPEED
VEHICLE
13
4
STOP
LAMP
SWITCH
V30
18
DB/RD
213
C280
VENT
SOLENOID SOLENOIDVACUUM
56C2
V35
18
LG/RD
TN/RD18 V36
3E43
B707
E43 B706 YL/RD18 V32
5C1C262
K29
18
WT/PK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL CONTROL SOLENOIDVENT CONTROLSPEED
WT/PK20 K29 V32
20
YL/RD STOP LAMP
SWITCH
SENSESPEED
CONTROL
ON/OFF
SWITCH SENSE
2
6
G300
BK20Z1
DB/RD20 V30
GENERATOR
FIELD DRIVER
K20
18
DG
8C1
2
GENERATOR
TRANSMISSION
RANGE
SWITCH
T41
SENSE
10
YL/DG18 T10
SENSE REQUEST MANAGEMENTTORQUE
TORQUE
MANAGEMENT
REQUIREMENT
SENSE 63
C2
7
ST-RUN V23
CENTER MESSAGESERVICE
ENGINE
SOON
LAMP
C122
INDICATOR SERVICE ENGINE SOON5
B70
E43
P34
B232
A2G3
20
BK/PK
BK/PK20 G3
BK/PK18 G3 *13
* RHD
RHD LHD
JUNCTION
BLOCK
TOGENERATOR
FIELD
DRIVER
LAMP DRIVER (8W-70-8) (8W-70-8)
(8W-31-5)
(8W-33-3) (8W-33-3)
(8W-15-7)(8W-20-2) (8W-31-4)
(8W-31-8)(8W-12-9)
(8W-46-3)
(8W-12-19)
NS/GS8W-30 FUEL/IGNITION SYSTEM
2.4L8W - 30 - 19
GS003019J988W-3