2004 CHRYSLER VOYAGER clock

AUTO TEMP CONTROL C3-4WAY
CAV CIRCUIT FUNCTION
1 F600 20LB/PK PROTECTED IGNITION
2 D40 20WT/LB KDB NO. 2 CLOCK
3 C905 20BR/LB SENSOR RETURN
4 D18 20WT/YL KDB NO. 2 DATA
AUTOMATIC DAY/NIGHT MIRROR (LUXURY) - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 F503 20BK/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z113 20BK GROUND
3 L1 20BK/WT BACK-UP LAMP FEED
4 P112 20BK/OR (EXCEPT EXPORT) MIRROR B(+)
5 P114 20BK/LB (EXCEPT EXPORT) MIRROR B(-)
6- -
7 L24 20BK/GY (EXCEPT EXPORT) AUTOMATIC HEADLAMP SWITCH SENSOR
BACK-UP LAMP SWITCH (MTX) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T2 18DG/WT TRS REVERSE SENSE
2 Z252 18BK/WT GROUND
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K25 20BR/TN (DIESEL) BATTERY TEMPERATURE SENSOR SIGNAL
1 K91 18DB/YL (GAS) BATTERY TEMP SIGNAL
2 K900 20DB/DG (DIESEL) SENSOR GROUND
2 K900 18DB/DG (GAS) SENSOR GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-13

CLOCKSPRING C1 - WHITE 6 WAY
CAV CIRCUIT FUNCTION
1 X920 22GY/OR RADIO CONTROL MUX RETURN
2 X20 22GY/WT RADIO CONTROL MUX
3 X3 22DG/VT HORN SWITCH SENSE
4 V37 22VT SPEED CONTROL SWITCH SIGNAL
5 K900 20DB/DG SENSOR GROUND
6- -
CLOCKSPRING C2 - YELLOW 4 WAY
CAV CIRCUIT FUNCTION
1 R61 18LG/VT DRIVER SQUIB 2 LINE 1
2 R63 18LG/WT DRIVER SQUIB 2 LINE 2
3 R43 18LG/BR DRIVER SQUIB 1 LINE 1
4 R45 18LG/OR DRIVER SQUIB 1 LINE 2
CLOCKSPRING C3 - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND
2 Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND
3 V37 20VT (DIESEL) SPEED CONTROL SWITCH SIGNAL
3 V37 20VT (DIESEL) SPEED CONTROL SWITCH SIGNAL
3 V37 20VT (GAS) S/C SWITCH NO. 1 SIGNAL
3 V37 20VT (GAS) S/C SWITCH NO. 1 SIGNAL
4 X3 20DG/VT HORN SWITCH SENSE
CLOCKSPRING C4-2WAY
CAV CIRCUIT FUNCTION
1 X10 20RD/DB RADIO CONTROL MUX
2 X20 20RD/BK RADIO CONTROL MUX RETURN
CLUTCH PEDAL INTERLOCK SWITCH (MTX) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 20YL/OR FUSED IGNITION SWITCH OUTPUT (START)
2 T751 20YL (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
2 Z429 20BK/OR (GAS) GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-57

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

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C313 (Rear Console) BK At Rear Console 34
C314 BK Left Side Liftgate 49
C315 (Power Liftgate) BK Right Side Liftgate 49
C316 (Power Sliding Door) BK Wire Track to Sliding Door N/S
C317 (Power Sliding Door) BK Right Sliding Door 32, 45
C318 (Trailer Tow) BK Left Quarter N/S
C320 DKGY Driver Power Seat on Seat Harness N/S
C321 DKGY Under Passenger Seat N/S
C322 (Memory) BK On Seat Harness to Body 32
C324 (Manual Sliding Door) BK Left Sliding Door N/S
C325 (Manual Sliding Door) BK Right Sliding Door 32
C326 YL At Driver Side Airbag N/S
C327 YL At Passenger Side Airbag N/S
C328 (Sunroof) Left Quarter Panel 47
C329 (Diesel) BK Near Fuel Tank N/S
C330 (Diesel) LTGY Near Throttle Body 15, 16
C331 (Diesel) BK/GY Left Rear Engine Compartment N/S
C332 (3 Zone ATC) BK/LTGN Near T/O for Right Rear Lamp
AssemblyN/S
C333 (Except Export DKGY Left Side Instrument Panel 21
Cabin Heater Assist C1 (Diesel) BK Top of Engine N/S
Cabin Heater Assist C2 (Diesel) BK Top of Engine N/S
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head
Right Side of Engine11 , 1 7
Camshaft Position Sensor
(Diesel)BK Rear of Cylinder Head 15, 16
CD Changer Behind CD Changer N/S
Center High Mounted Stop Lamp BK At Lamp 49
Clockspring - C1 WT Steering Column 20, 21, 22, 23, 31
Clockspring - C2 YL Steering Column 20, 21, 22, 23, 31
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 BK Steering Column N/S
Clutch Pedal Interlock Switch BK At Switch/Driver Side 42
Clutch Pedal Upstop Switch
(Diesel)RD At Switch/Driver Side 42
Controller Anti-Lock Brake BK Right Side of Engine Compartment 11, 16, 17, 18
Crank Case Ventilation Heater
(Diesel)BK Top of Cylinder Head 15
Crankshaft Position Sensor
(Diesel)BK Rear of Engine 16
Crankshaft Position Sensor (Gas) BK Rear of Engine 13, 17
Data Link Connector WT Lower Instrument Panel Near
Steering Column41, 42
Dosing Pump (Diesel) BK Top of Engine N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

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 on this
model (Fig. 1). The power distribution center mates
directly with the Front Control Module (FCM) to
form the IPM Fuse and Relay Center. The power dis-
tribution center (PDC) is a printed circuit board
based module that contains fuses and relays, while
the front control module contains the electronics con-
trolling the IPM and other functions. This IPM con-
nects directly to the battery positive via a four pin
connector. The ground connection is via two other
connectors. The IPM provides the primary means of
voltage distribution and protection for the entire
vehicle.
The molded plastic IPM housing includes a base
and cover. The IPM cover is easily opened or removed
for service access by squeezing the two marked cover
latches and has a fuse and relay layout map integral
to the inside surface of the cover. This IPM housing
base and cover are secured in place by an IPM
mounting bracket. This mounting bracket is designed
to allow the IPM to rotate counter-clockwise once the
locking tab is disengaged. The IPM mounting bracketis secured in place by bolts threaded into the left
front wheel house.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) via a four- pin connector on the bottom of the
module. The IPM cover is unlatched and opened or
removed to access the fuses or relays. Internal con-
nections of all of the power distribution center cir-
cuits is accomplished by a combination of bus bars
and a printed circuit board. Refer to the Wiring sec-
tion of the service manual for complete IPM circuit
schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard from the
vehicle. Refer to the Battery section for the proce-
dure.
(3) Remove the battery from the vehicle. Refer to
the Battery section for the procedure.
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 2).
(5) Rotate the IPM counter-clockwise to access and
disconnect the various electrical connectors (Fig. 3).
(6) Free the IPM from its mounting bracket by
removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.
Fig. 1 BATTERY THERMAL GUARD
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
Fig. 2 RELEASING INTEGRATED POWER MODULE
FROM ITS MOUNTING BRACKET
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS

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)

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 4).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 5).(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 4 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 5 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
POWER OUTLET (Continued)

OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick and observe oil level. Add
oil only when the level is at or below the ADD mark
(Fig. 86).
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Remove oil fill cap.
(3) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.
(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
(9) Lower vehicle and fill crankcase with specified
type and amount of engine oil. (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
(10) Install oil fill cap.
(11) Start engine and inspect for leaks.
(12) Stop engine and inspect oil level.
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
OIL FILTER
DESCRIPTION
The engine oil filter (Fig. 87) is a high quality full-
flow, disposable type. Replace the oil filter with a
Mopartor the equivalent.
REMOVAL
(1) Raise vehicle on hoist.
(2) Position an oil collecting container under oil fil-
ter location.
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(3) Using a suitable filter wrench, turn oil filter
(Fig. 87) counterclockwise to remove.
INSTALLATION
(1) Clean and check filter mounting surface. The
surface must be smooth, flat and free of debris or
pieces of gasket.
(2) Lubricate new oil filter gasket with clean
engine oil.
(3) Screw oil filter (Fig. 87) on until the gasket
contacts base. Tighten to 12 N´m (105 in. lbs.).
Fig. 86 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK
RSENGINE 2.4L9-53