2005 CHRYSLER VOYAGER 8w 10 40

Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
1 - Secondary Terminal Lock
8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATIONRS
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
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATIONRS

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-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch................. 8W-42
A/C Compressor Clutch Relay............ 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 Motor................ 8W-56
Adjustable Pedals Relay................ 8W-56
Adjustable Pedals Sensor............... 8W-56
Adjustable Pedals Switch............... 8W-56
Airbag.............................. 8W-43
Airbag On/Off Indicator Lamp............ 8W-43
Airbag Squibs........................ 8W-43
Ambient Temperature Sensor............ 8W-49
Amplifier............................ 8W-47
Antenna............................ 8W-47
ATC Remote Sensor.................... 8W-42
Auto Shut Down Relay................. 8W-30
Auto Temp Control.................... 8W-42
B-Pillar Switches...................... 8W-61
Back-Up Lamp Switch.................. 8W-51
Battery............................. 8W-20
Battery Temperature Sensor............. 8W-20
Belt Tension Sensor.................... 8W-43
Blend Door Actuators.................. 8W-42
Blower Motors........................ 8W-42
Blower Motor Relays................... 8W-42
Blower Motor Resistor.................. 8W-42
Body Control Module................... 8W-45
Boost Pressure Sensor.................. 8W-30
Brake Fluid Level Switch............... 8W-35
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-30, 33, 41, 43, 47
Clutch Pedal Interlock Switch............ 8W-21
Clutch Pedal Upstop Switch............. 8W-30
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
Defogger Relay....................... 8W-48
Door Ajar Switches.................... 8W-39
Door Courtesy Lamps.................. 8W-44
Door Lock Motor/Ajar Switches........... 8W-61
Door Lock Switches.................... 8W-61Component Page
Dosing Pump......................... 8W-30
DVD Screen.......................... 8W-47
DVD/CD Changer..................... 8W-47
ECM/PCM Relay...................... 8W-30
EGR Solenoid........................ 8W-30
Electronic Control Unit................. 8W-64
Engine Control Module................. 8W-30
Engine Coolant Temp Sensor............. 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Oil Pressure Switch.............. 8W-30
EVAP/Purge Solenoid.................. 8W-30
Evaporator Temperature Sensor.......... 8W-42
Floor Console Lamp................... 8W-44
Fog Lamps.......................... 8W-50
Folding Mirror Relay................... 8W-62
Front Blower Module.................. 8W-42
Front Cigar Lighter.................... 8W-41
Front Control Module.................. 8W-10
Front Fog Lamp Relay................. 8W-50
Front Intrusion Sensor................. 8W-39
Front Reading Lamps/Switch............ 8W-44
Front Wiper High/Low Relay............. 8W-53
Front Wiper On/Off Relay............... 8W-53
Fuel Heater.......................... 8W-30
Fuel Heater Relay..................... 8W-30
Fuel Injectors........................ 8W-30
Fuel Pressure Sensor.................. 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 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
Hands Free Module................. 8W-47, 55
Headlamp Leveling Motors.............. 8W-50
Headlamp Switch..................... 8W-50
Headlamp Washer Pump Motor.......... 8W-53
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
Hood Ajar Switch..................... 8W-39
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
Idle Air Control Motor.................. 8W-30
RS8W-02 COMPONENT INDEX8W-02-1

Component Page
Ignition Coil......................... 8W-30
Ignition Switch....................... 8W-10
Impact Sensors....................... 8W-43
Inlet Air Temperature Sensor............ 8W-30
Instrument Cluster.................... 8W-40
Instrument Panel Switch
Bank.................. 8W-43, 44, 52, 53, 63
Integrated Power Module............... 8W-10
Knock Sensor........................ 8W-30
Lamp Assemblies...................... 8W-51
License Lamp..................... 8W-51, 61
Lift Pump Motor...................... 8W-30
Lift Pump Relay...................... 8W-30
Liftgate Ajar Switch................ 8W-39, 61
Liftgate Cinch/Release Motor............ 8W-61
Liftgate Flood Lamps.................. 8W-44
Liftgate Pinch Sensors................. 8W-61
Low Beam Lamps..................... 8W-50
Manifold Absolute Pressure Sensor........ 8W-30
Mass Air Flow Sensor.................. 8W-30
Memory Seat/Mirror/Adjustable Pedals
Module...................... 8W-56, 62, 63
Memory Set Switch.................... 8W-63
Message Center.................... 8W-40, 46
Mode Door Actuator................... 8W-42
Multi-Function Switch............ 8W-50, 52, 53
Natural Vacuum Leak Detection Assembly . . 8W-30
Occupant Classification Module.......... 8W-43
Occupant Restraint Controller........... 8W-43
Overhead Console..................... 8W-49
Oxygen Sensors....................... 8W-30
Park Assist Display.................... 8W-56
Park Assist Module.................... 8W-56
Park Assist Sensors.................... 8W-56
Park Lamp Relay..................... 8W-10
Park Lamps.......................... 8W-50
Park/Turn Signal Lamps................ 8W-50
Parking Brake Switch.................. 8W-40
Power Folding Mirror Switch............ 8W-62
Power Liftgate Module................. 8W-61
Power Liftgate Motor.................. 8W-61
Power Mirror Switch................... 8W-62
Power Mirrors........................ 8W-62
Power Outlets........................ 8W-41
Power Seat Circuit Breaker.............. 8W-10
Power Seat Motors.................... 8W-63
Power Seat Position Sensors............. 8W-63
Power Seat Switches................... 8W-63
Power Window Circuit Breaker........... 8W-10
Power Window Motors.................. 8W-60
Power Window Switches................ 8W-60
Powertrain Control Module........... 8W-30, 31
PTCs............................... 8W-10
Radiator Fan Relaies................... 8W-42Component Page
Radiator Fans........................ 8W-42
Radio............................... 8W-47
Reading Lamps....................... 8W-44
Rear A/C-Heater Unit.................. 8W-42
Rear Auto Temp Control Switch.......... 8W-42
Rear Blower Control Switches............ 8W-42
Rear Blower Motor Power Module......... 8W-42
Rear Dome Lamp..................... 8W-44
Rear Intrusion Sensor.................. 8W-39
Rear Mode Motor..................... 8W-42
Rear Temperature Motor................ 8W-42
Rear View Mirror................ 8W-49, 55, 62
Rear Window Defogger Grid............. 8W-48
Rear Wiper Motor..................... 8W-53
Recirculation Door Actuator............. 8W-42
Remote Radio Switches................. 8W-47
Repeater Lamps...................... 8W-52
Seat Belt Switches.................... 8W-43
Seat Belt Tensioners................... 8W-43
Seat Weight Sensor.................... 8W-43
Sentry Key Remote Entry Module......... 8W-39
Siren............................... 8W-39
Sliding Door Control Modules............ 8W-61
Sliding Door Latch Sensing Switches...... 8W-61
Sliding Door Lock Motors............... 8W-61
Sliding Door Motors................... 8W-61
Speakers............................ 8W-47
Speed Control Servo................... 8W-33
Speed Control Switches................. 8W-33
Speed Sensors........................ 8W-31
Splices.............................. 8W-70
Starter Motor........................ 8W-21
Starter Motor Relay................... 8W-21
Sunroof Module....................... 8W-64
Sunroof Switch....................... 8W-64
Thatcham Alarm Indicator.............. 8W-39
Thatcham Alarm Module................ 8W-39
Throttle Position Sensor................ 8W-30
Traction Control Switch................. 8W-35
Trailer Tow Connector.................. 8W-54
Transmission Control Module............ 8W-31
Transmission Control Relay............. 8W-31
Transmission Range Sensor.............. 8W-31
Transmission Solenoid/Pressure Switch
Assembly.......................... 8W-31
Turn Signal Lamps.................... 8W-52
Vehicle Speed Sensor................... 8W-30
Vent Motors.......................... 8W-60
Visor/Vanity Lamps.................... 8W-44
Washer Fluid Level Switch.............. 8W-53
Washer Pump Motor................... 8W-53
Water In Fuel Sensor.................. 8W-30
Wheel Speed Sensors................... 8W-35
Wiper Module........................ 8W-53
8W - 02 - 2 8W-02 COMPONENT INDEXRS

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch...... 8W-10-22, 24, 45, 48
A/C Compressor
Clutch Relay......... 8W-10-22, 24, 44, 45, 48
Accessory Relay............... 8W-10-16, 31, 65
Adjustable Pedals Relay........... 8W-10-47, 60
Adjustable Pedals Switch.......... 8W-10-40, 47
Ambient Temperature Sensor.......... 8W-10-62
Amplifier....................... 8W-10-32, 50
Auto Shut Down Relay............ 8W-10-21, 41
Auto Temp Control.................. 8W-10-40
Back-Up Lamp Switch............... 8W-10-66
Battery............... 8W-10-13, 14, 15, 41, 48
Blower Motor Resistor............ 8W-10-19, 38
Body Control Module....... 8W-10-25, 40, 45, 49,
50, 52, 54, 55, 56, 57, 67, 68
Brake Fluid Level Switch............. 8W-10-65
Brake Lamp Switch........... 8W-10-26, 52, 67
Brake Transmission Shift Interlock
Solenoid........................ 8W-10-63
Cabin Heater Assist........... 8W-10-23, 43, 60
Camshaft Position Sensor............. 8W-10-44
Center High Mounted Stop Lamp....... 8W-10-67
Clockspring........................ 8W-10-61
Clutch Pedal Interlock
Switch.............. 8W-10-18, 37, 54, 55, 61
Controller Antilock
Brake...... 8W-10-18, 25, 36, 37, 50, 56, 62, 67
Crank Case Ventilation Heater......... 8W-10-49
Data Link Connector........... 8W-10-35, 62, 68
Defogger Relay............ 8W-10-19, 20, 39, 64
Driver Heated Seat Module........... 8W-10-50
Driver Power Seat Switch............ 8W-10-50
Driver Power Window Switch....... 8W-10-33, 34
DVD/CD Changer................... 8W-10-40
ECM/PCM Relay................. 8W-10-23, 43
EGR Solenoid...................... 8W-10-44
Engine Control Module . . . 8W-10-18, 23, 24, 37, 43,
44, 48, 62, 67
Floor Console Lamp................. 8W-10-32
Floor Console Power Outlet........ 8W-10-32, 35
Front Blower Module............. 8W-10-19, 38
Front Blower Motor Relay.... 8W-10-18, 19, 38, 64
Front Cigar Lighter.............. 8W-10-16, 32
Front Control Module....... 8W-10-15, 16, 17, 18,
19, 20, 22, 24, 26, 27,
28, 29, 30, 31, 35, 36,
37, 38, 39, 45, 47, 48,
53, 54, 55, 58, 59, 60,
61, 62, 63, 64, 65, 66,
67, 68, 69
Front Fog Lamp Relay......... 8W-10-15, 27, 64
Front Wiper High/Low Relay.... 8W-10-16, 30, 65Component Page
Front Wiper On/Off Relay....... 8W-10-16, 30, 60
Fuel Heater....................... 8W-10-49
Fuel Heater Relay............. 8W-10-24, 48, 65
Fuel Injector No. 1.................. 8W-10-42
Fuel Injector No. 2.................. 8W-10-42
Fuel Injector No. 3.................. 8W-10-42
Fuel Injector No. 4.................. 8W-10-42
Fuel Injector No. 5.................. 8W-10-42
Fuel Injector No. 6.................. 8W-10-42
Fuel Pressure Solenoid............... 8W-10-44
Fuel Pump Module............... 8W-10-22, 45
Fuel Pump Relay............. 8W-10-22, 45, 65
Fuse 1...................... 8W-10-15, 16, 27
Fuse 2...................... 8W-10-15, 28, 29
Fuse 3...................... 8W-10-15, 28, 29
Fuse 4................... 8W-10-15, 16, 17, 30
Fuse 5......................... 8W-10-16, 31
Fuse 6......................... 8W-10-16, 31
Fuse 8......................... 8W-10-17, 35
Fuse 9................ 8W-10-17, 18, 19, 36, 37
Fuse 10........................ 8W-10-19, 38
Fuse 11........................ 8W-10-16, 31
Fuse 12........................ 8W-10-19, 38
Fuse 13........................ 8W-10-20, 39
Fuse 14............ 8W-10-20, 21, 23, 39, 47, 60
Fuse 15......... 8W-10-20, 21, 22, 23, 24, 41, 43
Fuse 16.................. 8W-10-21, 23, 41, 43
Fuse 17............ 8W-10-21, 22, 23, 24, 45, 48
Fuse 18............... 8W-10-22, 24, 25, 45, 48
Fuse 19............... 8W-10-22, 24, 25, 26, 50
Fuse 20........................ 8W-10-25, 50
Fuse 21........................ 8W-10-25, 50
Fuse 22........................ 8W-10-25, 50
Fuse 23..................... 8W-10-25, 54, 55
Fuse 24........................ 8W-10-25, 52
Fuse 26..................... 8W-10-25, 26, 52
Fuse 27........................ 8W-10-26, 52
Fuse 28........................ 8W-10-16, 31
Fuse 30........................ 8W-10-26, 53
Fuse 31........................ 8W-10-26, 53
Fuse 32........................ 8W-10-26, 53
Fuselink....................... 8W-10-13, 14
G100............................. 8W-10-56
G101....................... 8W-10-41, 48, 68
G103............................. 8W-10-68
G300.......................... 8W-10-58, 59
Generator................... 8W-10-13, 14, 44
Glow Plug Relay................. 8W-10-13, 44
Hands Free Module................. 8W-10-40
Headlamp Switch................ 8W-10-29, 63
Headlamp Washer Pump Motor..... 8W-10-26, 53
Headlamp Washer Relay........ 8W-10-26, 53, 64
RS8W-10 POWER DISTRIBUTION8W-10-1