1996 CHRYSLER VOYAGER fuel pump

trunk release brake rotor service schedule check engine jump start terminals wiper fluid

Page 36 of 1938

CHRYSLER VOYAGER 1996 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended
pressure
2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bea

CONDITION POSSIBLE CAUSES CORRECTION
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended
pressure
2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bearings 3. Replace wheel bearing
4. Worn control arm bushings 4. Replace control arm bushing
5. Excessive friction in steering gear 5. Replace steering gear
6. Excessive friction in steering shaft
coupling6. Replace steering coupler
7. Excessive friction in strut upper
bearing7. Replace strut bearing
Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended
pressure
2. Radial tire lead 2. Perform lead correction procedure
3. Incorrect front wheel camber 3. Check and reset front wheel
camber
4. Power steering gear imbalance 4. Replace power steering gear
5. Wheel braking 5. Correct braking condition causing
lateral pull
Excessive Steering Free Play 1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to
specified torque
4. Loose or worn steering shaft
coupler4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive
belt4. Correctly adjust power steering
pump drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering
coupler7. Replace steering coupler
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct
the wheel alignment factors. The following part
inspection and the necessary corrections should be
made to those parts which influence the steering of
the vehicle.
(1) Check and inflate all tires to recommended
pressure. All tires should be the same size and in
good condition and have approximately the same
wear. Note the type of tread wear which will aid in
diagnosing, see Wheels and Tires, Group 22.
(2) Check front wheel and tire assembly for radial
runout.
(3) Inspect lower ball joints and all steering link-
age for looseness.
(4) Check for broken or sagged front and rear
springs.(5) Check vehicle ride height to verify it is within
specifications.
(6) AlignmentMUSTonly be checked after the
vehicle has the following areas inspected and or
adjusted. Recommended tire pressures, full tank of
fuel, no passenger or luggage compartment load and
is on a level floor or a properly calibrated alignment
rack.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER AND CAMBER
Front suspension Caster and Camber settings on
this vehicle are determined at the time the vehicle is
designed. This is done by determining the precise
2 - 4 SUSPENSIONNS
DIAGNOSIS AND TESTING (Continued)

Page 171 of 1938

CHRYSLER VOYAGER 1996 Service Manual fluid accumulators temporarily store brake fluid that
is decayed from the wheel brakes during an ABS
cycle. This stored brake fluid is then used by the
pump in the HCU to provide build pressure for th

fluid accumulators temporarily store brake fluid that
is decayed from the wheel brakes during an ABS
cycle. This stored brake fluid is then used by the
pump in the HCU to provide build pressure for the
brake hydraulic system.
Additionally on vehicles that are equipped with
only ABS (non-traction control vehicles) there is a
mini brake fluid accumulator on the secondary
hydraulic circuit which protects the master cylinder's
seals during an ABS stop. There is also a noise
damping chamber on the primary hydraulic circuit.
On ABS equipped vehicles with traction control, in
addition to the brake fluid accumulators there are
also two noise damping chambers in the HCU.
HCU PUMP/MOTOR
The HCU (Fig. 4) contains 2 pump assemblies, one
for the primary and one for the secondary hydraulic
circuit of the brake system. Both pumps are driven
by a common electric motor (Fig. 4) which is part of
the HCU. The pumps draw brake fluid from the fluid
accumulators to supply build pressure to the brakes
during an ABS stop. The pump motor runs during
the drive-off cycle as a check and during an ABS stop
and is controlled by the CAB. The Pump/Motor
Assembly is not a serviceable item. If the pump/mo-
tor requires replacement the complete HCU (Fig. 4)
(minus the CAB) must be replaced.
ABS FUSES
The fuse for the ABS pump motor and the ABS system
are located in the power distribution center (PDC) (Fig. 5).
The PDC is located on the drivers side of the engine com-
partment forward of the strut tower. The fuse for the ABS
warning lamp in the instrument panel message center is
located in the junction block.
On vehicles equipped with traction control, the
fuse for the traction control switch is also located in
the junction block.The junction block is located on the left hand front
cowl panel on the vehicle.
ABS RELAYS
On the Teves Mark 20 Antilock Brake System both
the pump motor relay and the system relay are
located in the CAB. If either of the relays is diag-
nosed as not functioning properly the CAB will need
to be replaced. Refer to Controller Antilock Brakes in
the Removal And Installation Section in this group of
the service manual for the procedure.
PROPORTIONING VALVES
One assembly containing two proportioning valves
are used in the system, one for each rear brake
hydraulic circuit. The proportioning valve is located
on the frame rail next to the fuel tank, forward of the
right rear shock absorber (Fig. 6). Be sure replace-
ment proportioning valve assemblies have the same
split point and slope as the proportioning valve being
replaced.
WHEEL SPEED SENSORS
One Wheel Speed Sensor WSS is located at each
front and rear wheel of the vehicle (Fig. 7), (Fig. 8)
and (Fig. 9). The wheel speed sensor sends a small
AC signal to the CAB. This signal is generated by
magnetic induction created when a toothed sensor
ring (tone wheel) (Fig. 7), (Fig. 8) and (Fig. 9) passes
the stationary magnetic wheel speed sensor. The
CAB converts the AC signal generated at each wheel
into a digital signal. If a wheel locking tendency is
detected by the CAB, it will then modulate hydraulic
pressure via the HCU to prevent the wheel(s) from
locking.
Fig. 4 Teves Mark 20 HCU Pump/Motor
Fig. 5 Fuse Locations In Power Distribution Center
NSBRAKES 5 - 89
DESCRIPTION AND OPERATION (Continued)

Page 577 of 1938

CHRYSLER VOYAGER 1996 Service Manual 8W-02 COMPONENT INDEX
Component Page
2-4 Pressure Switch.....................8W-31
2-4 Solenoid...........................8W-31
A/C Compressor Clutch..................8W-42
A/C Compressor Clutch Relay

8W-02 COMPONENT INDEX
Component Page
2-4 Pressure Switch.....................8W-31
2-4 Solenoid...........................8W-31
A/C Compressor Clutch..................8W-42
A/C Compressor Clutch Relay...........8W-10, 42
A/C Heater Control.....................8W-42
A/C On Indicator.......................8W-42
A/C Pressure Transducer..............8W-30, 42
A/C Switch............................8W-42
A/C Zone Door Actuator..................8W-42
ABS Warning Lamp..................8W-35, 46
Accelerator Pedal Position Sensor..........8W-30
Airbag Control Module...................8W-43
Airbag Indicator Lamp...................8W-43
Airbag Warning Lamp...................8W-46
All Wheel Drive Solenoid.................8W-31
Ambient Air Temperature Sensor...........8W-49
Ash Receiver Lamp.....................8W-44
Automatic Day/Night Mirror..............8W-44
Automatic Shut Down Relay............8W-10, 30
Splice Information......................8W-70
Back-Up Lamp.........................8W-51
Back-Up Switch.....................8W-44, 51
Battery...............................8W-20
Blend Door Actuator.....................8W-42
Body Control Module....................8W-45
Brake Pressure Switch...................8W-46
Brake Warning Lamp....................8W-46
Camshaft Position Sensor................8W-30
Center Dome Lamp.....................8W-44
Center High Mounted Stop Lamp..........8W-51
Cigar/Accessory Relay...................8W-41
Clockspring.......8W-10, 15, 30, 33, 39, 40, 41, 43
Cluster Illumination Lamps...............8W-40
Clutch Interlock Switch...............8W-12, 21
Clutch Interlock Switch Jumper......8W-12, 21, 31
Clutch Switch.......................8W-30, 33
Combination Flasher/DRL Module. . . .8W-50, 51, 52
Combination Relays.....................8W-54
Compass/Mini-Trip Computer..............8W-49
Control Sleeve Sensor....................8W-30
Controller Anti-Lock Brake...............8W-35
Courtesy Lamp Relay...........8W-10, 12, 44, 50
Crank Case Heater......................8W-30
Crankshaft Position Sensor...............8W-30
Cruise Indicator Lamp...................8W-40
Data Link Connector....................8W-30
Diesel Power Relay...................8W-10, 30
Dome Lamp Switch.....................8W-50
Door Ajar Indicator Lamp................8W-40
Door Ajar Switches................8W-39, 40, 44
Door Lock Relay........................8W-61
Speakers..............................8W-47Component Page
Door Unlock Relay......................8W-61
Oxygen Sensors........................8W-30
Door Ajar Switches.............8W-39, 40, 44, 45
Door Arm/Disarm Switches.............8W-39, 61
Door Courtesy Lamps....................8W-44
Door Lock Motors.......................8W-61
Door Lock Switches.....................8W-61
Door Unlock Relays.....................8W-61
Heated Seat Backs......................8W-63
Heated Seat Cushions...................8W-63
Heated Seat Modules....................8W-63
Heated Seat Switches....................8W-63
Power Mirrors.........................8W-62
Power Seat Switches....................8W-63
Power Window Switches..................8W-60
Seat Motors...........................8W-63
Window Motors........................8W-60
Radiator Fans.........................8W-42
Dump Solenoid.........................8W-33
EGR Solenoid..........................8W-30
Electric Wiper De-Icer...................8W-48
Electronic PRNDL Indicator...............8W-40
Engine Coolant Temperature Gauge.........8W-40
Engine Coolant Temperature Lamp.........8W-46
Engine Coolant Temperature Sensor........8W-30
Engine Oil Pressure Switch...............8W-46
Engine Speed Sensor....................8W-30
Engine Starter Motor....................8W-21
Engine Starter Motor Relay............8W-10, 21
Evap Leak Detection Pump...............8W-30
Evap/Purge Solenoid....................8W-30
Evaporator Temperature Sensor............8W-42
Express Down Module...................8W-60
Flexible Fuel Sensor.....................8W-30
Fog Lamps............................8W-50
Fog Lamp Relay........................8W-50
Front Blower Motor.....................8W-42
Front Blower Motor Relay.............8W-10, 42
Front Blower Motor Resistor Block.........8W-42
Front Cigar Lighter/Power Outlet..........8W-41
Front Reading Lamp Defeat Switch.........8W-44
Front Reading Lamps/Switch..............8W-44
Front Washer Motor.....................8W-53
Front Wiper Switch.....................8W-53
Fuel Gauge............................8W-40
Fuel Heater...........................8W-30
Fuel Heater Relay...................8W-10, 30
Fuel Injectors..........................8W-30
Fuel Pump Module......................8W-30
Fuel Pump Relay....................8W-10, 30
Fuel Quantity Actuator..................8W-30
Fuel Shutdown Solenoid..................8W-30
NS/GS8W - 02 COMPONENT INDEX 8W - 02 - 1

Page 581 of 1938

CHRYSLER VOYAGER 1996 Service Manual 8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch........................8W-10-29
A/C Compressor Clutch Relay................8W-10-10, 25, 29
Airbag Control Module........................8

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch........................8W-10-29
A/C Compressor Clutch Relay................8W-10-10, 25, 29
Airbag Control Module........................8W-10-35
Automatic Shut Down Relay....................8W-10-9, 23
Battery.............................8W-10-8, 27, 28
Body Control Module...........8W-10-11, 14, 16, 17, 19, 21, 30, 32
BS15..................................8W-10-33
BS16..................................8W-10-34
BS19..................................8W-10-30
BS33..................................8W-10-25
Center Dome Lamp..........................8W-10-21
Cigar/Accessory Relay......................8W-10-10, 31
Clockspring..............................8W-10-30
Combination Flasher/DRL Module................8W-10-29, 32
Controller Anti-Lock Brake....................8W-10-15, 29
Courtesy Lamp Relay.........................8W-10-21
Crank Case Heater..........................8W-10-27
CS01..................................8W-10-21
CS02..................................8W-10-20
CS1 ..................................8W-10-21
Data Link Connector.........................8W-10-11
Diesel Power Relay.......................8W-10-9, 25, 29
Door Lock Relay............................8W-10-13
Door Unlock Relay..........................8W-10-13
Downstream Heated Oxygen Sensor.................8W-10-23
Driver Door Courtesy Lamp.....................8W-10-21
Driver Door Unlock Relay......................8W-10-13
Driver Power Mirror.......................8W-10-12, 22
EGR Solenoid.............................8W-10-25
Engine Starter Motor.......................8W-10-8, 16
Engine Starter Motor Relay....................8W-10-8, 16
ES01................................8W-10-27, 28
ES06................................8W-10-25, 29
ES07..................................8W-10-29
ES09..................................8W-10-8
ES11 ................................8W-10-8, 28
ES12..................................8W-10-23
ES26..................................8W-10-8
ES28..................................8W-10-8
ES29................................8W-10-25, 29
ES40..................................8W-10-27
ES99..................................8W-10-24
Fog Lamp Relay............................8W-10-33
Front Blower Motor..........................8W-10-18
Front Blower Motor Relay.....................8W-10-8, 18
Front Cigar Lighter/Power Outlet..................8W-10-31
Front Reading Lamps/Switch.....................8W-10-20
Front Wiper Switch..........................8W-10-19
FS01..................................8W-10-24
FS03..................................8W-10-23
Fuel Heater..............................8W-10-27
Fuel Heater Relay.........................8W-10-9, 27
Fuel Injector No. 1........................8W-10-23, 24
Fuel Injector No. 2........................8W-10-23, 24
Fuel Injector No. 3........................8W-10-23, 24
Fuel Injector No. 4........................8W-10-23, 24
Fuel Injector No. 5..........................8W-10-24
Fuel Injector No. 6..........................8W-10-24
Fuel Pump Module..........................8W-10-25
Fuel Pump Relay..........................8W-10-9, 26
Fuel Tank Module...........................8W-10-26
Fuse 1 (JB)..............................8W-10-17
Fuse 1 (PDC)...........................8W-10-14, 35
Fuse 2 (JB)............................8W-10-11, 16
Fuse 2 (PDC).............................8W-10-35
Fuse 3 (JB)..............................8W-10-17
Fuse 4 (JB)..............................8W-10-17
Fuse 4 (PDC).......................8W-10-10, 32, 33, 34
Fuse 5 (JB)..............................8W-10-17
Fuse 5 (PDC).......................8W-10-10, 32, 33, 34
Fuse 6 (JB)..............................8W-10-16
Fuse 6 (PDC).......................8W-10-10, 32, 33, 34
Fuse 7 (JB)..............................8W-10-12
Fuse 7 (PDC).......................8W-10-10, 32, 33, 34
Fuse 8 (JB)..............................8W-10-16
Fuse 8 (PDC)...........................8W-10-10, 31
Fuse 9 (JB)..............................8W-10-16
Fuse 9 (PDC)...........................8W-10-10, 30
Fuse 10 (JB)..............................8W-10-16
Fuse 10 (PDC)...........................8W-10-10, 29
Fuse 11 (JB)..............................8W-10-14
Fuse 11 (PDC)...........................8W-10-10, 29
Fuse 12 (JB)............................8W-10-14, 18
Fuse 12 (PDC)...........................8W-10-10, 29
Fuse 13 (PDC)...........................8W-10-10, 29
Fuse 15 (PDC)...........................8W-10-9, 28
Fuse 16 (JB)..............................8W-10-27
Fuse 16 (PDC)...........................8W-10-9, 26
Fuse 17 (PDC).......................8W-10-9, 23, 25, 29
Fuse 18 (PDC)...........................8W-10-9, 20Component Page
Fuse 19 (PDC)...........................8W-10-8, 19
Fuse 20 (PDC)...........................8W-10-8, 19
Fuse 21 (PDC)...........................8W-10-8, 18
Fuse 22 (PDC)...........................8W-10-8, 17
Fuse 23 (PDC)...........................8W-10-8, 16
Fuse 24 (PDC)...........................8W-10-8, 15
Fuse 25 (PDC)...........................8W-10-8, 15
Fuse 26 (PDC)...........................8W-10-8, 13
Fuse 27 (PDC)...........................8W-10-8, 12
Fuse 28 (PDC)...........................8W-10-9, 11
Fusible Link A11............................8W-10-8
Fusible Link A54............................8W-10-8
G100................................8W-10-27, 28
G103................................8W-10-27, 28
G200................................8W-10-14, 32
G300............................8W-10-14, 18, 19, 31
Generator............................8W-10-8, 23, 25
Glove Box Lamp............................8W-10-20
Glow Plug Relay..........................8W-10-8, 25
Headlamp Dimmer Switch......................8W-10-32
Headlamp Switch.........................8W-10-21, 34
High Beam Relay.....................8W-10-10, 32, 33, 34
High Note Horn............................8W-10-30
Horn Relay............................8W-10-10, 30
Horn Switch..............................8W-10-30
HS6D S02...............................8W-10-13
Ignition Coil Pack...........................8W-10-23
Ignition Switch........................8W-10-11, 14, 16
Instrument Cluster........................8W-10-11, 14
Junction Block..........8W-10-11, 12, 13, 14, 16, 17, 18, 20, 21, 22,
26, 27, 29, 30, 31, 32, 35
Key-In Halo Lamp..........................8W-10-21
Left Headlamp..........................8W-10-33, 34
Left Headlamp Leveling Motor....................8W-10-34
Left High Headlamp.........................8W-10-33
Left Liftgate Flood Lamp.......................8W-10-21
Left Mid Reading Lamp.....................8W-10-20, 21
Left Rear Reading Lamp.....................8W-10-20, 21
Left Visor/Vanity Mirror Lamps...................8W-10-20
Low Beam Relay.....................8W-10-10, 32, 33, 34
Low Note Horn............................8W-10-30
Memory Seat/Mirror Module.....................8W-10-11
Message Center......................8W-10-11, 14, 33, 34
Name Brand Speaker Relay.....................8W-10-16
Park Lamp Relay..........................8W-10-8, 17
Passenger Door Courtesy Lamp...................8W-10-21
Passenger Power Mirror.....................8W-10-12, 22
Power Distribution Center .8W-10-8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,
20, 23, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35
Power Mirror Fold Relay.......................8W-10-22
Power Mirror Switch.........................8W-10-20
Power Mirror Unfold Relay....................8W-10-21, 22
Power Seat Circuit Breaker.....................8W-10-13
Powertrain Control Module............8W-10-16, 23, 25, 26, 27, 29
PTC 1 (JB)......................8W-10-16, 26, 27, 29, 35
PTC 3 (JB)..............................8W-10-13
PTC 7 (JB)............................8W-10-16, 31
PTC 8 (JB)..............................8W-10-16
PTC 9 (JB)..............................8W-10-16
Radiator Fan Relay..........................8W-10-15
Radiator Fan Relay No. 1.......................8W-10-25
Radiator Fan Relay No. 2.....................8W-10-15, 25
Radiator Fan Relay No. 3.....................8W-10-19, 25
Radio..................................8W-10-11
Rear Cigar Lighter/Power Outlet...................8W-10-31
Rear Dome Lamp...........................8W-10-21
Rear Window Defogger........................8W-10-12
Rear Window Defogger Relay.....................8W-10-12
Remote Keyless Entry Module....................8W-10-11
Right Headlamp..........................8W-10-33, 34
Right Headlamp Leveling Motor...................8W-10-34
Right High Headlamp.........................8W-10-33
Right Liftgate Flood Lamp......................8W-10-21
Right Low Headlamp.........................8W-10-33
Right Mid Reading Lamp.....................8W-10-20, 21
Right Rear Reading Lamp....................8W-10-20, 21
Right Visor/Vanity Mirror Lamps..................8W-10-20
Sentry Key Immobilizer Module...................8W-10-20
Stop Lamp Switch...........................8W-10-29
Transmission Control Module..................8W-10-16, 28
Transmission Control Relay....................8W-10-9, 28
Transmission Control Solenoids...................8W-10-28
Universal Garage Door Opener....................8W-10-20
Upstream Heated Oxygen Sensor..................8W-10-23
Vehicle Speed Sensor.......................8W-10-27, 29
Washer Module............................8W-10-13
Wiper High/Low Relay........................8W-10-19
Wiper Module.............................8W-10-19
Wiper On Relay..........................8W-10-8, 19
NS/GS8W - 10 POWER DISTRIBUTION 8W - 10 - 1

Page 582 of 1938

CHRYSLER VOYAGER 1996 Service Manual 86
853087
87
85
30
86
POWER
DISTRIBUTION
CENTER
27
1
86
30
85
87
87
85
30
86
87
85
30
86
87
85
30
86
86
30
85
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87
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30
86
86873085
85
308786
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87 87
85
30
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Page 585 of 1938

CHRYSLER VOYAGER 1996 Service Manual - -FUEL PUMP RELAY OUTPUT A141 16DG/WTFUSED IGNITION (ST-RUN) F87 18 WT/BKFUEL PUMP RELAY CONTROL K31 18BR INTERNAL FUSED B (+)
87A86 85
30
FUEL PUMP RELAY (GAS)
FUNCTION CAVITY CIRCUITCIRCUIT CAVITY

Page 589 of 1938

CHRYSLER VOYAGER 1996 Service Manual CENTER DISTRIBUTION
POWER
BLOCK JUNCTION
TO
30
20A
FUSE
15
10C8
A5
18
RD/DB
MODULE
TO
TRANSMISSION
CONTROL
RELAY CONTROL
TRANSMISSION
AUTOMATIC
SHUT
DOWN
RELAY
17FUSE20A
30
TO
JUNCTION
BLOCK
PK/VT20 F

Page 605 of 1938

CHRYSLER VOYAGER 1996 Service Manual DG/OR18 A142DG/OR18 A142
10 9
B108 E963
A142
18
DG/ORA142
18
DG/ORA142
18
DG/OR
A142
18
DG/OR
18 A142
DG/OR
RELAY FAN
RADIATOR
4
NO. 3
RELAY FAN
RADIATOR
4
NO. 2 NO. 1
4
RADIATOR
FAN
RELAY
RELAY PLUG

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