2002 CHRYSLER VOYAGER Brake

(2) Turn off ignition.
(3) Remove the air bag, refer to the restraint sec-
tion for more information.
(4) Remove the screw from bottom of the switch.
(5) Remove switch from steering wheel.
(6) Disconnect two-way electrical connector.
(7) Repeat for the other switch.
INSTALLATION
The speed control switches are mounted in the
steering wheel and wired through the clock spring
device under the airbag module.
WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO THE RESTRAINT SYS-
TEMS SECTION FOR MORE INFORMATION.
(1) Connect two-way electrical connector.
(2) Install switch.
(3) Install screw for the switch.
(4) Repeat for the other switch.
(5) Install the air bag, refer to the restraint section
for more information.
(6) Install the negative battery cable.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is located in the engine com-
partment. It is made of plastic.
OPERATION
The reservoir stores engine vacuum. Manifold vac-
uum is supplied from the brake booster check valve.
The speed control vacuum supply hose has a check
valve at the source (brake booster) to maintain the
highest available vacuum level in the servo, reservoir
and vacuum hoses. When engine vacuum drops, as in
climbing a grade while driving, the reservoir supplies
the vacuum needed to maintain proper speed control
operation. The vacuum reservoir cannot be repaired
and must be replaced if faulty.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect the negative battery cable.
(3) Disconnect the vacuum line to the battery tray/
vacuum reservoir.
(4) Remove battery tray/vacuum reservoir, refer to
the Battery section for more information.
INSTALLATION
(1) Install battery tray/vacuum reservoir, refer to
the Battery section for more information.
(2) Connect vacuum line that leads to the battery
tray/vacuum reservoir.
(3) Connect the negative battery cable.
8P - 6 SPEED CONTROLRS
SWITCH (Continued)
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DIAGNOSIS AND TESTING - FAILED PARK
SWITCH
If the wiper park switch has failed, the windshield
wipers will operate as follows:
²SWITCH OFF- Wipers stop in current location
regardless of the park signal.
²INTERMITTENT MODE- Wipers operate con-
tinuously or at low speed for one or more extra
wipes.
²LOW SPEED- Wipers operate at low speed.²HIGH SPEED- Wipers operate at high speed.
²WIPE AFTER WASH- Wipers operate at low
speed in any mode setting. Wipers operate only while
the wash button is depressed with switch in the OFF
mode and wipers stop in mid-cycle when button is
released.
The windshield wiper park switch and circuit is
monitored by the BCM. The park switch and circuit
can be tested using the WIPER SYSTEM DIAGNO-
SIS table.
WIPER SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
WIPER BLADES DO NOT
PARK PROPERLY1. WIPER ARMS IMPROPERLY
PARKED.1. REMOVE WIPER ARMS AND REPARK.
REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
2. WIPER ARMS ARE LOOSE ON
PIVOT SHAFT.2. REMOVE WIPER ARM AND REPARK.
REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
3. MOTOR CRANK LOOSE AT
OUTPUT SHAFT.3. REMOVE WIPER ARM, RUN WIPER
MOTOR TO PARK POSITION AND
REMOVE THE MODULE. WITHOUT
ROTATING THE MOTOR OUTPUT SHAFT,
REMOVE THE CRANK AND CLEAN ANY
FOREIGN MATTER FROM THE MOTOR
SHAFT. INSTALL THE MOTOR CRANK IN
ITS ORIGINAL POSITION.
4. STRIPPED WIPER ARM HEAD. 4. REPLACE WIPER ARM.
MOTOR STOPS IN ANY
POSITION WHEN THE
SWITCH IS TURNED OFFOPEN PARK CIRCUIT. CHECK PARK SWITCH BY
DISCONNECTING THE WIRE
CONNECTOR AND APPLY BATTERY
VOLTAGE TO PIN 4. PLACE A JUMPER
WIRE FROM PIN 2 TO PIN 3 AND THEN
TO AN EXTERNAL GROUND. REPLACE
MOTOR IF MOTOR DOES NOT PARK.
MOTOR WILL NOT STOP
WHEN THE SWITCH IS
TURNED OFF1. FAULTY SWITCH. 1. CHECK SWITCH IN LOW, HIGH AND
INTERMITTENT POSITION.
2. LACK OF DYNAMIC BRAKE ON
WET GLASS.2. ENSURE PARK SWITCH HAS CLEAN
GROUND.
WIPER BLADES SLAP
AGAINST COWL SCREEN
OR WINDOW MOLDINGS.WIPER ARMS ARE PARKED
INCORRECTLY.PARK WIPER ARMS. REFER TO WIPER
ARM ADJUSTMENT.
BLADES CHATTER 1. FOREIGN SUBSTANCE SUCH
AS POLISH ON GLASS OR
BLADES.1. CLEAN GLASS AND BLADE ELEMENT
WITH NON-ABRASIVE CLEANER.
2. ARMS TWISTED, BLADE AT
WRONG ANGLE ON GLASS.2. REPLACE ARM.
RSWIPERS/WASHERS8R-3
WIPERS/WASHERS (Continued)
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CLEANING
Wiper blades exposed to the weather for a long
period of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is recommended
to remove the accumulation of salt and road grime.
The wiper blades, arms and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the wiper blades continue
to streak or smear, they should be replaced. The
wiper blade should run smoothly across the wind-
shield in both directions. The wiper blade should
slightly roll over center when the blade reverses
direction. A wiper blade insert that has lost flexibility
or a wiper arm that has lost spring tension, will
cause the blade to skip or chatter across the wind-
shield. If the wiper blades are new and the wiper
arm spring tension is OK and a chattering sound is
emitted from the wiper(s), the wiper blade is not roll-
ing over center. If this condition exists, (refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
ADJUSTMENTS).
INSTALLATION
(1) Position the blade onto the arm.
(2) Engage the blade to the retainer by pulling up
on the blade until the tabs snap into position (Fig. 8).
WIPER LINKAGE
REMOVAL
(1) Remove the front windshield wiper unit from
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(2) Place the wiper unit on a suitable work sur-
face.
(3) Remove nuts holding the cowl cover brackets to
the wiper unit.
(4) Remove cowl cover brackets from the wiper
unit.
(5) Remove nuts holding linkage to the wiper unit.
(6) Remove the wiper linkage from the wiper unit.
(7) Disconnect the wire connectors from back of
the wiper motor.
INSTALLATION
(1) Connect the wire harness connector.
(2) Install the linkage on the wiper unit.
(3) Install the nut holding the linkage to the wiper
unit.
(4) Install the cowl cover brackets to the wiper
nut.
(5) Install the front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).(6) Install the cowl cover.
(7) Install the wiper arms and blades.
WIPER MODULE
REMOVAL
(1) Release the hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the wiper arms.
(4) Remove the cowl cover (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the positive lock on the wiper mod-
ule wire connector (Fig. 10).
(6) Disconnect the wiper module wire connector
from the engine compartment wire harness.
(7) Disconnect the windshield washer hose from
coupling outside the module.
(8) Disconnect the drain tubes from nipples on bot-
tom of the wiper module.
(9) Remove nuts holding wiper module to lower
windshield fence.
(10) Remove bolts holding the wiper module to the
dash panel (Fig. 11).
(11) Lift wiper module from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(12) Remove wiper module.
Fig. 10 WIPER MODULE WIRE CONNECTOR
1 - WIPER SYSTEM WIRE CONNECTOR
2 - LOCK TAB
3 - POSITIVE LOCK
4 - WIPER MODULE
RSWIPERS/WASHERS8R-19
WIPER BLADES (Continued)
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INSTALLATION
(1) Position the wiper module into the cowl.
(2) Install the bolts that secure the wiper module
to the dash (Fig. 11).
(3) Install the nuts that retain the wiper module.
(4) Connect the drain tubes to the nipples on the
wiper module.
(5) Connect the windshield washer tube.
(6) Connect the wire harness connector to the
wiper module (Fig. 11).
(7) Connect the positive lock on the wiper module
wire connector (Fig. 10).
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(8) Install the cowl cover (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION).
(9) Install the wiper arms and blades.
(10) Connect the battery negative cable.
(11) Close the hood.
Fig. 11 WIPER MODULE
1 - BOLT
2 - NUTS
3 - BOLT
4 - WIPER MODULE
5 - WINDSHIELD
8R - 20 WIPERS/WASHERSRS
WIPER MODULE (Continued)
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WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1MESSAGE CENTER................... 8W-46-1
AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION SYSTEM........ 8W-97-1 RSWIRING
8W-1
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DESCRIPTION - CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric
code to identify the wire and it's function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second-
ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a par-
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam-
ple, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire
splice and provide references to other sections the
splices serves. Section 8W-70 only contains splice dia-
grams that are not shown in their entirety some-
where else in the wiring diagrams.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the dia-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09General information and Diagram
Overview
8W-10 thru
8W-19Main Sources of Power and
Vehicle Grounding
8W-20 thru
8W-29Starting and Charging
8W-30 thru
8W-39Powertrain/Drivetrain Systems
8W-40 thru
8W-49Body Electrical items and A/C
8W-50 thru
8W-59Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru
8W-69Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATIONRS
WIRING DIAGRAM INFORMATION (Continued)
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DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located in the engine compart-
ment are C100 series numbers
²In-line connectors located in the Instrument
Panel area are C200 series numbers.
²In-line connectors located in the body are C300
series numbers.
²Jumper harness connectors are C400 series
numbers.
²Grounds and ground connectors are identified
with a ªGº and follow the same series numbering as
the in-line connectors.
²Splices are identified with an ªSº and follow the
same series numbering as the in-line connectors.
²Component connectors are identified by the com-
ponent name instead of a number. Multiple connec-
tors on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/
ground/splice location charts in section 8W-91 refer-
ence the figure numbers of the illustrations.
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component. The abbre-
viation N/S means Not Shown in the illustrations
WARNING
WARNINGS - GENERAL
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-7
WIRING DIAGRAM INFORMATION (Continued)
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8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch Relay............ 8W-42
A/C Compressor Clutch................. 8W-42
A/C- Heater Control.................... 8W-42
A/C Pressure Sensor................... 8W-42
A/C-Heater Control.................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Accessory Relay....................... 8W-10
Adjustable Pedals Module............... 8W-30
Adjustable Pedals Switch................ 8W-30
Airbag Control Module.................. 8W-43
Ambient Temp Sensor.................. 8W-49
Antenna............................. 8W-47
Auto Shut Down Relay................. 8W-30
Auto Temp Control..................... 8W-42
Automatic Day/Night Mirror............. 8W-49
Back-Up Lamp Switch.................. 8W-51
Battery Temperature Sensor............. 8W-20
Battery............................. 8W-20
Blend Door Actuators................... 8W-42
Body Control Module................... 8W-45
Boost Pressure Sensor.................. 8W-30
B-Pillar Switches...................... 8W-61
Brake Lamp Switch................. 8W-30, 51
Brake Transmission Shift Interlock
Solenoid........................... 8W-31
Cabin Heater Assist.................... 8W-30
Camshaft Position Sensor............... 8W-30
CD Changer.......................... 8W-47
Center High Mounted Stop Lamp......... 8W-51
Cinch/Release Motors................... 8W-61
Clockspring.................. 8W-33, 41, 43, 47
Clutch Pedal Interlock Switch Jumper..... 8W-10
Clutch Pedal Interlock Switch............ 8W-10
Combination Relays.................... 8W-54
Controller Antilock Brake............... 8W-35
Crank Case Ventilation Heater........... 8W-30
Crankshaft Position Sensor.............. 8W-30
Cylinder Lock Switches................. 8W-39
Data Link Connector................... 8W-18
Diagnostic Junction Port................ 8W-18
Door Ajar Switches.................... 8W-39
Door Lock Motor/Ajar Switches........... 8W-61
Door Lock Switches.................... 8W-61
Driver Airbag......................... 8W-43
EGR Solenoid......................... 8W-30
Electric Wiper De-Icer.................. 8W-48
Engine Control Module................. 8W-30
Engine Coolant Temp Sensor............. 8W-30
Engine Oil Pressure Switch.............. 8W-30
EVAP/Purge Solenoid................... 8W-30
Evaporator Temperature Sensor.......... 8W-42
Floor Console Lamp.................... 8W-44Component Page
Fog Lamps........................... 8W-50
Front Blower Module................... 8W-42
Front Blower Motor Relay............... 8W-42
Front Blower Motor.................... 8W-42
Front Cigar Lighter.................... 8W-41
Front Control Module.................. 8W-10
Front Fog Lamp Relay.................. 8W-50
Front Intrusion Sensor................. 8W-39
Front Washer Pump Motor.............. 8W-53
Front Wiper On/Off Relay............... 8W-53
Fuel Heater.......................... 8W-30
Fuel Injectors........................ 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Pump Module.................... 8W-30
Full Open Switches.................... 8W-61
Fuselink............................. 8W-10
Fuses............................... 8W-10
Generator............................ 8W-20
Glow Plug Relay...................... 8W-30
Glow Plugs........................... 8W-30
Grounds............................. 8W-15
Halo Lamp........................... 8W-44
Headlamp Leveling Motors.............. 8W-50
Headlamp Switch...................... 8W-50
Headlamp Washer Relay................ 8W-53
Headlamps........................... 8W-50
Heated Seat Backs..................... 8W-63
Heated Seat Cushions.................. 8W-63
Heated Seat Modules................... 8W-63
High Beam Lamps..................... 8W-50
High Note Horn....................... 8W-41
Horn Relay.......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coil.......................... 8W-30
Ignition Switch....................... 8W-10
Inlet Air Temperature Sensor............ 8W-30
Instrument Cluster.................... 8W-40
Instrument Panel Switch Bank . . 8W-44, 52, 53, 63
Integrated Power Module................ 8W-10
Knock Sensor......................... 8W-30
License Lamp......................... 8W-51
Lift Pump Motor...................... 8W-30
Liftgate Ajar Switch................. 8W-39, 61
Liftgate Cinch/Release Motor............. 8W-61
Liftgate Cylinder Lock Switch............ 8W-39
Liftgate Flood Lamps................... 8W-44
Liftgate Right Pinch Sensor.............. 8W-61
Low Beam Lamps.................... 8W-50-9
Manifold Absolute Pressure Sensor........ 8W-30
Mass Air Flow Sensor.................. 8W-30
Memory Seat/Mirror Module.......... 8W-62, 63
Memory Set Switch.................... 8W-63
RS8W-02 COMPONENT INDEX8W-02-1
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