2005 CHRYSLER VOYAGER ipm

DIAGNOSIS AND TESTING - WASHER SYSTEM
WASHER SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
WASHER MOTOR 1. IPM FUSE #33 BLOWN OR
DEFECTIVE.1. CHECK FUSE #33 IN THE IPM.
REPLACE IF NOT OK.
2. IPM FUSE #33 LOOSE. 2. PROPERLY INSTALL IPM FUSE #33 IN
SOCKET.
BLOWN FUSE WHEN
IGNITION SWITCH IS IN
THE RUN OR ACCESSORY
POSITION.1. SHORT IN IPM BETWEEN
FUSE #33 AND PIN 11 OR PIN
1.1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. SHORT IN MOTOR POWER
CIRCUIT.2. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 11 AND WASHER
MOTOR CONNECTOR POSITIVE
TERMINAL 2. IF NOT OK, REPAIR CIRCUIT.
3. SHORT IN WASHER PUMP
MOTOR.3. REPLACE WASHER PUMP MOTOR.
WASHER MOTOR RUNS
WHEN IGNITION SWITCH
IN RUN OR ACCESSORY
POSITION.1. SHORT IN IPM BETWEEN
WASHER PUMP MOTOR LSD
AND PIN 20.1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. DEFECTIVE FRONT
WASHER LSD IN IPM.2. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
3. SHORT IN MOTOR GROUND
CIRCUIT.3. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 20 AND MOTOR
CONNECTOR NEGATIVE TERMINAL 1. IF
NOT OK, REPAIR CIRCUIT.
RSWIPERS/WASHERS8R-5
WIPERS/WASHERS (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
WASHER SYSTEM WILL
NOT FLOW WASHER
FLUID.1. NO WASHER FLUID IN
RESERVOIR.1. FILL WASHER RESERVOIR.
2. IPM FUSE #33 BLOWN. 2. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 11 AND WASHER
PUMP MOTOR CONNECTOR POSITIVE
TERMINAL 2. INTERNAL SHORT IN IPM. IF
NOT OK, REPAIR CIRCUIT OR REFER TO
IPM DIAGNOSTIC PROCEDURES IN
WIRING DIAGRAMS.
3. WASHER HOSE NOT
FLOWING WASHER FLUID.3. ASSURE WASHER HOSE IS NOT
PINCHED, LOOSE, BROKEN OR
DISCONNECTED. IF NOT OK, PROPERLY
ROUTE OR REPAIR WASHER HOSE.
4. MOTOR CONNECTOR
LOOSE.4. PROPERLY SEAT AND LOCK
CONNECTOR TO MOTOR.
5. MOTOR CONNECTOR
TERMINALS BENT.5. REPAIR TERMINALS AND PROPERLY
SEAT CONNECTOR TO MOTOR.
6. OPEN CIRCUIT TO OR
FROM WASHER SELECT
SWITCH (EXPORT AND ATC
EQUIPPED VEHICLES ONLY).6. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM BODY CONTROLLER PIN
27 AND WASHER SELECT SWITCH PIN 4,
OR OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM BODY CONTROLLER PIN
22 AND WASHER SELECT SWITCH PIN 2.
IF NOT OK, REPAIR CIRCUIT.
7. OPEN OR DEFECTIVE
WASHER SELECT SWITCH.7. REFERO TO THE PROPER BODY
DIAGNOSTIC PROCEDURES
INFORMATION ON MANUAL
TEMPERATURE CONTROLS.
8. OPEN POWER CIRCUIT TO
MOTOR.8. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM CONNECTOR TERMINAL 11
AND WASHER MOTOR CONNECTOR
POSITIVE TERMINAL 2. INTERNAL OPEN
IN IPM. IF NOT OK, REPAIR CIRCUIT OR
REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
9. OPEN OR DEFECTIVE
MOTOR GROUND CIRCUIT.9. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM CONNECTOR TERMINAL
20 AND WASHER MOTOR CONNECTOR
NEGATIVE TERMINAL 1. INTERNAL OPEN
IN IPM. IF NOT OK, REPAIR CIRCUIT OR
REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
10. OPEN CIRCUIT IN MOTOR. 10. CHECK FOR OPEN CIRCUIT IN MOTOR
BETWEEN POSITIVE TERMINAL 2 AND
NEGATIVE TERMINAL 1. IF NOT OK,
REPLACE WASHER MOTOR.
11. SEIZED MOTOR BEARINGS. 11. APPLY DIRECT BATTERY VOLTAGE TO
MOTOR TERMINALS. IF MOTOR DOES
NOT RUN, REPLACE MOTOR.
8R - 6 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
12. NO BUS MESSAGE FROM
MTC CONTROL (MANUAL
TEMP. CONTROL ONLY).12. CHECK FOR CORRECT PCI BUS
MESSAGE WITH DRBIIIT.
COWL GRILLE NOZZLE
WILL NOT FLOW.1. FROZEN NOZZLE. 1. MOVE VEHICLE INTO HEATED AREA TO
ALLOW TIME TO THAW NOZZLE. ASSURE
WASHER FLUID IS PROPERLY BLENDED
FOR AMBIENT OUTSIDE TEMPERATURES.
2. NOZZLE HOSE NOT
FLOWING.2. ASSURE NOZZLE HOSE IS NOT
PINCHED, LOOSE, BROKEN, OR
DISCONNECTED. IF NOT OK, PROPERLY
ROUTE OR REPAIR NOZZLE HOSE.
3. NOZZLE HOSE PLUGGED
BY CONTAMINATION.3. CLEAN NOZZLE HOSE OF
CONTAMINATION. DETERMINE SOURCE
OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
4. NOZZLE PLUGGED BY
CONTAMINATION.4. CLEAN NOZZLE OF CONTAMINATION
OR REPLACE NOZZLE. DETERMINE
SOURCE OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
5. DEFECTIVE WASHER HOSE
CHECK VALVE.5. REPLACE COWL GRILLE PANEL
WASHER HOSE/CHECK VALVE ASSEMBLY.
WASHER FLUID OUTPUT IS
LOW.1. PARTIALLY PINCHED HOSE. 1. ASSURE WASHER HOSE IS NOT
PARTIALLY PINCHED. IF NOT OK,
PROPERLY ROUTE HOSE.
2. FRONT REAR VALVE
DEFECTIVE.2. REPLACE WASHER PUMP.
3. WORN OUT WASHER PUMP. 3. REPLACE WASHER PUMP.
COWL GRILLE NOZZLE
STREAM OVERSHOOTS
WINDSHIELD.1. NOZZLE NOT SEATED IN
COWL GRILLE.1. ASSURE NOZZLE IS SNAPPED IN
PLACE.
WIPER WILL NOT CYCLE
WHEN WASHER SELECT
SWITCH IS DEPRESSED.1. DEFECTIVE IPM. 1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. DEFECTIVE IPM/BODY
CONTROLLER.2. REFER TO IPM/BODY CONTROLLER
DIAGNOSTIC PROCEDURES IN WIRING
DIAGRAMS.
3. REAR WIPER OUTPUT
SHORT FAULT.3. A GROUND SHORT DETECTED
BETWEEN BCM AND REAR WIPER
MOTOR. CLEAR FAULT. IF IT WON'T
CLEAR, REPAIR SHORT
4. REAR WIPER OUTPUT
OPEN FAULT.4. AN OPEN CIRCUIT DETECTED
BETWEEN BCM AND REAR WIPER
MOTOR. CLEAR FAULT. IF IT WON'T
CLEAR, REPAIR OPEN CIRCUIT.
RSWIPERS/WASHERS8R-7
WIPERS/WASHERS (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
5. NO BUS MESSAGE FROM
MTC CONTROL (MANUAL
TEMP. CONTROL ONLY).5. REFER TO PROPER BODY DIAGNOSTIC
INFORMATION OR USE DRBIIITTO CHECK
PROPER MESSAGE STATUS.
WASHER OPERATES
INTERMITTENTLY.1. INTERMITTENT MOTOR
GROUND.INTERMITTENT GROUND BETWEEN
MOTOR CONNECTOR TERMINAL 1 AND
IPM PIN 20.
2. INTERMITTENT OPEN IN
WASHER SELECT SWITCH.2. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/MULTI-FUNCTION
SWITCH - DIAGNOSIS AND TESTING).
3. DEFECTIVE WASHER
MOTOR.3. REPLACE WASHER PUMP.
LOW WASHER FLUID
LEVEL INDICATOR
INOPERATIVE.1. LOOSE FLUID LEVEL
SENSOR CONNECTOR.1. PROPERLY SEAT CONNECTOR TO LOW
FLUID LEVEL SENSOR AND LOCK.
2. OPEN POWER CIRCUIT TO
FLUID LEVEL SENSOR.2. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM CONNECTOR TERMINAL 7
AND THE LOW FLUID LEVEL SENSOR
CONNECTOR TERMINAL 2. IF NOT OK,
REPAIR CIRCUIT.
3. OPEN GROUND CIRCUIT. 3. OPEN OR DEFECTIVE CIRCUIT
BETWEEN FLUID LEVEL SENSOR
CONNECTOR TERMINAL 1 AND FLOOR
GROUND 1.
4. DEFECTIVE IPM. 4. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
5. FLUID LEVEL SENSOR
SWITCH OPEN OR
DEFECTIVE.5. APPLY OHMMETER TO THE SWITCH
TERMINALS TO CHECK FOR COMPLETE
CIRCUIT. CYCLE SWITCH FLOAT BACK
AND FORTH BY FILLING AND DEPLETING
RESERVOIR OF WASHER FLUID TO
CHECK FOR PROPER SWITCH FUNCTION.
IF NOT OK, REPLACE LOW FLUID LEVEL
SENSOR SWITCH.
LEAKING WASHER FLUID. 1. PUMP OR SENSOR
GROMMET DEFECTIVE.1. PROPERLY SEAT PUMP OR SENSOR IN
GROMMET. IF NOT OK, REPLACE PUMP
OR SENSOR GROMMET.
2. LEAKING WASHER PUMP. 2. REPLACE WASHER PUMP.
3. LEAKING FLUID LEVEL
SENSOR.3. REPLACE FLUID LEVEL SENSOR.
4. LEAKING OR DEFECTIVE
RESERVOIR BODY.4. REPLACE RESERVOIR BODY.
8R - 8 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)

TERMINOLOGY
This is a list of terms and definitions used in the
wiring diagrams.
LHD.................Left Hand Drive Vehicles
RHD ...............Right Hand Drive Vehicles
ATX . . Automatic Transmissions-Front Wheel Drive
MTX . . . Manual Transmissions-Front Wheel Drive
AT....Automatic Transmissions-Rear Wheel Drive
MT .....Manual Transmissions-Rear Wheel Drive
SOHC...........Single Over Head Cam Engine
DOHC..........Double Over Head Cam Engine
Export . . Vehicles Built For Sale In Markets Other
Than North America
Except Export.... Vehicles Built For Sale In North
America
DESCRIPTION - CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code
which identifies the main circuit, part of the main
circuit, gage of wire, and color (Fig. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
Fig. 4 WIRE CODE IDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-5
WIRING DIAGRAM INFORMATION (Continued)

FRONT CONTROL MODULE - BLACK 49 WAY
CAV CIRCUIT FUNCTION
1 A1 B(+)
2 A1 B(+)
3 L43 LEFT LOW BEAM DRIVER
4 L34 RIGHT HIGH BEAM DRIVER
5 L33 LEFT HIGH BEAM DRIVER
6 L44 RIGHT LOW BEAM DRIVER
7- -
8 Z117, Z118, Z343, Z344 GROUND
9 A1 B(+)
10 FCM 10 HORN RELAY CONTROL
11 - -
12 P201 (EXCEPT EXPORT) ADJUSTABLE PEDALS RELAY CONTROL
13 FCM 13 PARK LAMP RELAY CONTROL
14 FCM 14 FRONT WIPER ON/OFF RELAY CONTROL
15 C41 (DIESEL) CABIN HEATER ASSIST CONTROL
16 W7 FRONT WIPER PARK SWITCH SENSE
17 X3 HORN SWITCH SENSE
18 W1 WASHER FLUID LEVEL SWITCH SENSE
19 FCM 19 FUSED IGNITION SWITCH OUTPUT (START)
20 FCM 20 FUSED (+)
21 L78 FUSED PARK LAMP RELAY OUTPUT (RIGHT)
22 D25 PCI BUS
23 G931 (DIESEL) AMBIENT TEMPERATURE SENSOR RETURN
24 - NOT USED
25 G31 (DIESEL) AMBIENT TEMPERATURE SENSOR SIGNAL
26 L13 (EXPORT) HEADLAMP ADJUST SIGNAL
27 F1, F2 FCM OUTPUT (UNLOCK-RUN-START)
28 - NOT USED
29 F100 ORC RUN ONLY DRIVER
30 FCM 30 FRONT/REAR BLOWER MOTOR RELAY CONTROL
31 FCM 31 DEFOGGER RELAY CONTROL
32 FCM 32 (EXPORT) HEADLAMP WASHER RELAY CONTROL
33 FCM 33 FRONT FOG LAMP RELAY CONTROL
34 FCM 34 FRONT WIPER HIGH/LOW RELAY CONTROL
35 FCM 35 ACCESSORY RELAY CONTROL (RUN-ACC)
36 B20 BRAKE FLUID LEVEL SWITCH SENSE
37 F20 FUSED IGNITION SWITCH OUTPUT (RUN-START)
38 A1 B(+) (WHEN IPM C5 CPA IS NOT ENGAGED)
39 T2 (MTX) TRS REVERSE SENSE
40 - NOT USED
41 L77 FUSED PARK LAMP RELAY OUTPUT (LEFT)
42 D123 FLASH PROGRAM ENABLE
43 Z116 GROUND
44 L50 (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
44 L50 (GAS) BRAKE LAMP SWITCH OUTPUT
45 W10 FRONT WASHER PUMP MOTOR CONTROL
46 W20 REAR WASHER PUMP MOTOR CONTROL
47 K32 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
48 F201 ORC RUN-START DRIVER
49 - -
8W - 80 - 72 8W-80 CONNECTOR PIN-OUTSRS

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)