2005 CHRYSLER VOYAGER wiring

STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 7).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.
STANDARD PROCEDURE - TESTING FOR
CONTINUITY
(1) Remove the fuse for the circuit being checked
or, disconnect the battery.
(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 8).
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND
(1) Remove the fuse and disconnect all items
involved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch
the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen-
eral area of the wiring harness.
Fig. 7 TESTING FOR VOLTAGE POTENTIAL
Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-9
WIRING DIAGRAM INFORMATION (Continued)

STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the suspected fused circuits.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting or energizing the items in the
fuse circuit one at a time. When the fuse blows the
circuit with the short to ground has been isolated.
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 9).
(2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 9 TESTING FOR VOLTAGE DROP
PROBING TOOL PACKAGE 6807
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
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WIRING DIAGRAM INFORMATION (Continued)

CONNECTOR
REMOVAL
(1) Disconnect battery.
(2) Release Connector Lock (Fig. 10).
(3) Disconnect the connector being repaired from
its mating half/component.
(4) Remove the dress cover (if applicable) (Fig. 10).
(5) Release the Secondary Terminal Lock, if
required (Fig. 11).
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector
(Fig. 12).
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec-
tor, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-11

Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
1 - Secondary Terminal Lock
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CONNECTOR (Continued)

Fig. 12 TERMINAL REMOVAL
1 - TYPICAL CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680
3 - APEX CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680
5 - AUGAT CONNECTOR
6 - SPECIAL TOOL 69327 - MOLEX CONNECTOR
8 - SPECIAL TOOL 6742
9 - THOMAS AND BETTS CONNECTOR
10 - SPECIAL TOOL 6934
11 - TYCO CONNECTOR
12 - SPECIAL TOOL 8638
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-13
CONNECTOR (Continued)

DIODE
REMOVAL
(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. 13).
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 13).
(3) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one±half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1±1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
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WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 14).
(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 15).(5) Solder the connection together using rosin core
type solder only (Fig. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) 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 (Fig. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-15

8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.Connector, ground, and splice indexes are provided.
Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
appropriate index for the proper figure number. For
items that are not shown in this section N/S is placed
in the Fig. column.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
A/C Compressor Clutch LTGY Top of A/C Compressor 10, 11, 15, 17, 18
A/C Pressure Sensor GY At Throttle Body 9, 10, 15, 16, 17
A/C-Heater Control C1 (MTC) BK/RD Rear of Control 20, 23, 25
A/C-Heater Control C2 (MTC) BK/BL Rear of Control 20, 23, 25
Accelerator Pedal Position
Sensor (Diesel)At Accelerator Pedal 42
Adjustable Pedals Module
(Except Export)Near Brake Lamp Switch N/S
Adjustable Pedals Motor On Pedal Support N/S
Adjustable Pedals Relay (Except
Export)Left Side Engine Compartment 6
Adjustable Pedals Sensor On Adjustable Pedals Motor N/S
Adjustable Pedals Switch (Except
Export)Left Side Kick Panel 41
Ambient Temperature Sensor
(Except Base)BK On Radiator Closure Panel 1
Amplifier C1 NAT Right Quarter Panel 48
Amplifier C2 NAT Right Quarter Panel 48
ATC Remote Sensor Above ATC Control N/S
Auto Temp Control C1 NAT Rear of Control 20
Auto Temp Control C2 BK Rear of Control 20
Auto Temp Control C3 (MTX) Rear of Control N/S
Back-Up Lamp Switch BK On Transmission 16
Battery Temperature Sensor BK At Battery N/S
Blower Motor Resistor C1 (MTC) BK Right Side of HVAC N/S
Blower Motor Resistor C2 (MTC) BK Right Side of HVAC N/S
Body Control Module C1 BK Under Left Instrument Panel 41, 42
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-1