Chrysler Voyager 2000 3.0L Workshop Manual

chrysler :: Chrysler Truck Voyager V6-3.0L VIN 3
(2000)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations

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> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8

Accessory Delay Relay: Diagrams

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information >

Locations > Page 9

Voyager V6-3.0L VIN 3 (2000)

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> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams

Sentry Key Immobilizer Module

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 13

Alarm Module: Adjustments
PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE

NOTE

: IF THE PCM AND THE SKIM ARE REPLACED AT THE SAME TIME, PROGRAM THE VIN INTO THE PCM FIRST. ALLVEHICLE KEYS WILL THEN NEED TO BE REPLACED AND PROGRAMMED TO THE NEW SKIM.

1. Turn the ignition ON (transmission in park/neutral).2. Use the DRB and select "THEFT ALARM", "SKIM" then MISCELLANEOUS.3. Select "SKIM MODULE REPLACEMENT (GASOLINE)"4. Program the vehicle four-digit PIN into the SKIM.5. Select "COUNTRY CODE" and enter the correct country.

NOTE

: BE SURE TO ENTER THE CORRECT COUNTRY CODE. IF THE INCORRECT COUNTRY CODE IS PROGRAMMED INTO SKIM, THE SKIM MUST BE REPLACED.

6. Select "UPDATE VIN" (the SKIM will learn the VIN from the PCM).7. Press "ENTER" to transfer the VIN (the PCM will send the VIN to the SKIM).8. The DRB will ask if you want to transfer the secret key. Select "ENTER" to transfer secret key from the PCM. This will ensure the current
vehicle ignition keys will still operate the SKIS system.

PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE

1. Turn the ignition ON (transmission in park" neutral).2. Use the DRB and select "THEFT ALARM", "SKIM" then "MISCELLANEOUS".3. Select "PROGRAM IGNITION KEYS".4. Enter secured access mode by entering the vehicle four-digit PIN.

NOTE:

A MAXIMUM OF EIGHT KEYS CAN BE LEARNED TO EACH SKIM. ONCE A KEY IS LEARNED TO A SKIM IT (THEKEY) CANNOT BE TRANSFERRED TO ANOTHER VEHICLE.

If ignition key programming is unsuccessful, the DRB will display one of the following messages:

- The DRB attempts to read the programmed key status and there are no keys programmed in the SKIM memory.Programming Not Attempted

Programming Key Failed

- (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following:-

faulty ignition key transponder

- ignition key is programmed to another vehicle.

8 Keys Already Learned, Programming Not Done

- SKIM transponder ID memory is full.1. Obtain ignition keys to be programmed from customer (8 keys maximum)2. Using the DRB, erase all ignition keys by selecting "MISCELLANEOUS" and "ERASE ALL CURRENT IGN. KEYS"3. Program all ignition keys.

- Ignition key transponder ID is currently programmed in SKIM memory.Learned Key In Ignition

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 17

Remote Keyless Entry Module

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 18

Keyless Entry Module: Adjustments

1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System.2. Insert ignition key into the ignition switch.3. the ignition switch to RUN position without starting engine.4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds).5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the
RKE module is set to receive the new Vehicle Access Code(s).

6. Within of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of30 seconds

the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and wassuccessful.

7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total).8. Programming mode will last for . To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify30 seconds

that the RKE module will no longer accept additional Vehicle Access Code(s).

9. When Vehicle Access Codes(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using
each key fob.

NOTE:

Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. If any key fob isreplaced, the memory seat and mirror module will require programming. Refer to Power Seat Systems for proper (data link) programming with theDRB III scan tool.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 19

Keyless Entry Module: Service and Repair
REMOVAL

Negative Battery Cable

1. Disconnect and isolate the battery negative cable.2. Remove instrument panel top cover.3. Remove screws holding RKE module to instrument panel.

RKE Module

4. Disconnect wire connector from RKE module.5. Remove the RKE module from vehicle.

INSTALLATION

For installation, reverse the above procedures.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 24

Remote Keyless Entry Module

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 25

Keyless Entry Module: Adjustments

1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System.2. Insert ignition key into the ignition switch.3. the ignition switch to RUN position without starting engine.4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds).5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the
RKE module is set to receive the new Vehicle Access Code(s).

6. Within of the chime, press and release the "LOCK" and "UNLOCK" buttons on the transmitter at the same time. Then press any one of30 seconds

the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of the transmitter has been completed and wassuccessful.

7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total).8. Programming mode will last for . To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify30 seconds

that the RKE module will no longer accept additional Vehicle Access Code(s).

9. When Vehicle Access Codes(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using
each key fob.

NOTE:

Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. If any key fob isreplaced, the memory seat and mirror module will require programming. Refer to Power Seat Systems for proper (data link) programming with theDRB III scan tool.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 26

Keyless Entry Module: Service and Repair
REMOVAL

Negative Battery Cable

1. Disconnect and isolate the battery negative cable.2. Remove instrument panel top cover.3. Remove screws holding RKE module to instrument panel.

RKE Module

4. Disconnect wire connector from RKE module.5. Remove the RKE module from vehicle.

INSTALLATION

For installation, reverse the above procedures.

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations

Power Door Lock Relay: Locations

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 30

Voyager V6-3.0L VIN 3 (2000)

Junction Block

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 31

Power Door Lock Relay: Diagrams

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 32

Voyager V6-3.0L VIN 3 (2000)

Junction Block

Door Lock Relay

Door Unlock Relay

Driver Door Unlock Relay

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations

Seat Heater Control Module: Locations

The HSCM for each seat is installed on front portion of each cushion pan.

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 36

Seat Heater Control Module: Description and Operation

(HSCM)

The Heated Seat Control Module is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules areused in the vehicle, one for each front seat. The HSCM for each seat is installed on front portion of each cushion pan. The wire harness connector issecured by an integral clip to the inside surface of the outboard seat cushion frame.

Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat cushion temperature sensor circuits), an ignition.switched battery feed, a non-switched battery feed, and a ground. The only HSCM output is the feed for the seat heating elements.
The HSCM cannot be repaired and, if faulty or damaged, it must be replaced.

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 37

Seat Heater Control Module: Testing and Inspection

Before testing the heated seat control module, test the heated seat switch, the heated seat elements, and the heated seat sensor as described. If testing ofthe heated seat switch, elements, and sensor reveals no problems, proceed as follows.

1. Replace the heated seat control module with a known good unit and test the operation of the heated seats. If OK, discard the faulty heated seat
control module. If not OK, go to Step 2.

2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat sensor to the heated seat control module. Repair any
short or open circuits as required.

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 38

Seat Heater Control Module: Service and Repair
REMOVAL

1. Disconnect and isolate the battery negative cable.2. Remove the seat assembly from the vehicle.3. With seat upside down on bench, remove the wiring harness connector from the module.4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan.5. Remove module from seat cushion pan.

INSTALLATION

For installation, reverse the above procedures.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations

Controller Antilock Brake (CAB)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 43

Connector Pin Identification

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 44

Electronic Brake Control Module: Service and Repair
REMOVAL

NOTE:

To replace the Hydraulic Control Unit (HCU) or the Controller Antilock Brake (CAB) on this vehicle, the entire Integrated Control Unit(ICU) needs to be removed from the vehicle. The CAB can then be separated from the HCU. Do not attempt to replace the CAB with the ICUmounted in the vehicle.

1. Remove the ICU from the vehicle. Refer to Integrated Control Unit, Service and Repair, Removal and Installation.

Pump/Motor To CAB Wiring Harness

2. Disconnect the pump/motor wiring harness from the CAB.

CAB Attaching Bolts

3. Remove the 4 bolts attaching the CAB to the HCU.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 45

Voyager V6-3.0L VIN 3 (2000)

4. Remove the CAB from the HCU.

INSTALLATION

1. Install the CAB on the HCU.2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of .2 Nm (17 inch lbs.)

3. Plug the pump/motor wiring harness into the CAB.4. Install the ICU in the vehicle.5. Bleed the base and ABS hydraulic systems. Refer to Brake Bleeding, Service and Repair. Antilock Brake System Bleeding.6. Road test the vehicle to ensure proper operation of the base brakes and ABS.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations

Radiator Cooling Fan Motor Relay: Locations

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 50

Voyager V6-3.0L VIN 3 (2000)

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Radiator Fan Relay

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions

Radiator Cooling Fan Motor Relay: Diagram Information and Instructions

How to Find System & Component Diagrams

Group Index Complete Body and Chassis Diagrams

When trying to find the diagram for a specific component or system, use the information under .See: Diagrams/Electrical Diagrams

Complete Body and Chassis Diagrams

GroupIndex

Whenever a reference exists to another sheet or figure, find the corresponding diagram in , using the . The reference number for the subsequent diagram will match a listed group shown.See: Diagrams/Electrical Diagrams

How to Use Wiring Diagrams

DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use thewiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 53

Voyager V6-3.0L VIN 3 (2000)

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 54

Voyager V6-3.0L VIN 3 (2000)

General Information (Part 1 of 2)

Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placednear the bottom of the page (Fig. 1).

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 55

Voyager V6-3.0L VIN 3 (2000)

General Information (Part 2 of 2)

All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2).

Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the componentindicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the componentis shown complete.

It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a shortpiece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only.

Circuit Functions

Circuit Identification Code Chart

All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to theCircuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models.

Circuit Information

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 56

Voyager V6-3.0L VIN 3 (2000)

Wire Code Identification

Wire Color Code Chart

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 57

Voyager V6-3.0L VIN 3 (2000)

Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color.

Connector and Splice Information

CAUTION:

Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental RestraintSystem connectors. Always check parts availability before attempting a repair.

CONNECTOR AND SPLICE IDENTIFICATION

The connector and splice numbering used for this vehicle is different than the numbering used for other vehicles. This numbering change is due to theunique wiring harnesses used in this vehicle.
The connector and splice numbering for this vehicle has a letter prefix to identify what harness the connector/splice is located in. A list of these letter

designations follows:

- AW - All wheel drive harness

- B - Body or EDW harness

- C - Dome harness

- D - Door harness

- E - Engine harness

- F - Fuel rail harness

- H - Heated seat harness

- J - Jumper harness

- L - Liftgate harness

- P - Instrument panel harness

- RC - Radio control harness

- RS - Radiator fan harness

- S - Seat harness

- T - Trailer tow harness

When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally thesplice number. An example of this would be ESO2.

- E - Indicates splice is in the engine harness

- S - Indicates a splice

- 02 - Indicates what splice it is in the harness

Electrostatic Discharge (ESD) Sensitive Devices

Electrostatic Discharge Symbol

All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with thefollowing procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is notknown whether the part is ESD sensitive, assume that it is.

1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding
across a seat, sitting down from a standing position, or walking a distance.

2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.3. When using a voltmeter, be sure to connect the ground lead first.4. Do not remove the part from its protective packing until it is time to install the part.5. Before removing the part from its package, ground the package to a known good ground on the vehicle.

Notes, Cautions and Warnings

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

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Voyager V6-3.0L VIN 3 (2000)

Additional important information is presented in three ways: Notes, Cautions, and Warnings.

NOTES

are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate differentconditions that may appear on the vehicle. For example, an up-to and after condition.

are used to indicate information that could prevent making an error that may damage the vehicle.CAUTIONS

WARNINGS

provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time avehicle is being serviced.

WARNING:

- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.

- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.

- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON.

­SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. AMANUAL TRANSMISSION SHOULD BE IN NEUTRAL.

- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.

- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.

­TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAILPIPE, CATALYTIC CONVERTER, AND MUFFLER.

- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY.

- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING.

Positive Temperature Coefficient

Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in thejunction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids.

Positive Temperature Coefficient Symbol

A special symbol is used to identify these in the wiring diagrams.

Symbols

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 59

Voyager V6-3.0L VIN 3 (2000)

Wiring Diagram Symbols

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 60

Voyager V6-3.0L VIN 3 (2000)

International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3).

Take Outs

The abbreviation is used in the component location section to indicate a point in which the wiring harness branches out to a component.T/O

Terminology

This is a list of terms and definitions used in the wiring diagrams.

LHD ............................................................................................................................................................................................... Left Hand Drive VehiclesRHD ............................................................................................................................................................................................. Right Hand Drive VehiclesATX ................................................................................................................................................................. Automatic Transmissions-Front Wheel DriveMTX ..................................................................................................................................................................... Manual Transmissions-Front Wheel Drive

AT ..................................................................................................................................................................... Automatic Transmissions-Rear Wheel DriveMT ........................................................................................................................................................................ Manual Transmissions-Rear Wheel DriveSOHC ..................................................................................................................................................................................... Single Over Head Cam EngineDOHC ................................................................................................................................................................................... Double Over Head Cam EngineBUX ............................................................................................................................................................................................................. Built-Up-ExportBuilt-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America

Section Identification and Information

Section Identification

Connector and Terminal Replacement
CONNECTOR AND TERMINAL REPLACEMENT

1. Disconnect battery.2. Disconnect the connector (that is to be repaired) from its mating half/component.3. Cut off the existing wire connector directly behind the insulator. Remove of tape from the harness.6 inches

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

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Voyager V6-3.0L VIN 3 (2000)

The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires,connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. Itcan, however, be shown partially in another group if it contains some associated wiring.

Stagger Cutting Wires

4. Stagger cut all wires on the harness side at intervals.1/2 inch

1 inch

5. Remove of insulation from each wire on the harness side.6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.

1 inch

7. Remove of insulation from each wire.8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.9. Spread the strands of the wire apart on each part of the exposed wires.

10. Push the two ends of wire together until the strands of wire are close to the Insulation.11. Twist the wires together.12. Solder the connection together using rosin core type solder only. Do not use acid core solder.13. 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

1-1/2 inches 2 inches

14. Repeat steps 8 through 13 for each wire.15. Re-tape the wire harness starting behind the connector and past the repair.16. Re-connect the repaired connector.17. Connect the battery, and test all affected systems.

Connector Replacement
CONNECTOR REPLACEMENT

1. Disconnect battery.2. Disconnect the connector that is to be repaired from its mating half/component

Connector Locking Wedge

3. Remove the connector locking wedge, if required.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 62

Voyager V6-3.0L VIN 3 (2000)

Terminal Removal

Terminal Removal Using Special Tool

4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the
terminal from the connector.

5. Reset the terminal locking tang, if it has one.6. Insert the removed wire in the same cavity on the repair connector.7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector
pinout identification, refer to the wiring diagrams.

8. Insert the connector locking wedge into the repaired connector, if required.9. Connect connector to its mating half/component.

10. Connect battery and test all affected systems.

Diode Replacement
REMOVAL

1. Disconnect the battery.2. Locate the diode in the harness, and remove the protective covering.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 63

Voyager V6-3.0L VIN 3 (2000)

Diode Identification

3. Remove the diode from the harness, pay attention to the current flow direction.

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 systems.

Terminal Replacement
REMOVAL

1. Disconnect battery.2. Disconnect the connector being repaired from its mating half/component.

Fig.16 Connector Locking Wedge Tab (Typical)

3. Remove the connector locking wedge, if required (Fig. 16).

Fig.17 Terminal Removal

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 64

Voyager V6-3.0L VIN 3 (2000)

Fig.18 Terminal Removal Using Special Tool

4. Position the connector locking finger away from the terminal using the proper pick from special tool kit . Pull on the wire to remove the6680

terminal from the connector (Fig. 17) (Fig. 18).

5. Cut the wire 6 inches from the back of the connector.6. Remove of insulation from the wire on the harness side.1 inch

INSTALLATION

one-half (1/2) inch

1. Select a wire from the terminal repair assembly that best matches the color wire being repaired.2. Cut the repair wire to the proper length and remove of insulation.3. Splice the repair wire to the wire harness

a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.b. Spread the strands of the wire apart on each part of the exposed wires.c. Push the two ends of wire together until the strands of wire are close to the insulation.d. Twist the wires together.e. Solder the connection together using rosin core type solder only. Do not use acid core solder.f.

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 ofboth ends of the tubing.

1-1/2 inches 2 inches

4. Insert the repaired wire into the connector.5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component.6. Re-tape the wire harness starting at behind the connector and past the repair.7. Connect battery and test all affected systems.

Terminal/Connector Repair-Augat Connectors
REMOVAL

1. Disconnect battery.2. Disconnect the connector from its mating half/component.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

Instructions > Page 65

Voyager V6-3.0L VIN 3 (2000)

Fig.8 Augat Connector Repair

3. Push down on the yellow connector locking tab to release the terminals (Fig. 8).

Fig.9 Using Special Tool 6932

6932

4. Using special tool , push the terminal to remove it from the connector (Fig. 9).5. Repair or replace the terminal as necessary.

INSTALLATION

1. Reset the terminal locking tang.2. Insert the removed wire in the same cavity on the repair connector.3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and

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Voyager V6-3.0L VIN 3 (2000)

4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out.5. Connect connector to its mating half/component.6. Connect battery and test all affected systems.

Terminal/Connector Repair-Molex Connectors
REMOVAL

1. Disconnect battery2. Disconnect the connector from its mating half/component.

Fig.10 Molex Connector Repair

3. Insert special tool into the terminal end of the connector (Fig. 10).6742

Fig.11 Using Special Tool 6742

6742

4. Using special tool , release the locking fingers on the terminal (Fig. 11).5. Pull on the wire to remove it from the connector.6. Repair or replace the terminal as necessary.

INSTALLATION

1. Reset the terminal locking tang.2. Insert the removed wire in the same cavity on the repair connector.3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out

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Voyager V6-3.0L VIN 3 (2000)

identification, refer to the wiring diagrams.

4. Connect connector to its mating half/component.5. Connect battery and test all affected systems.

Wiring Repair

When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to preventdamage to the insulation.

1 inch

1. Disconnect battery negative cable.2. Remove of insulation from each end of the wire.3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.

Wire Repair

4. Spread the strands of the wire apart on each part of the exposed wire (Example 1).5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2).6. Twist the wires together (Example 3).7. Solder the connection together using rosin core type solder only. 8. 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 bothDo not use acid core solder.

ends of the tubing.

9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.

10. Connect battery and test all affected systems.

Special Tools

Probing Tool Package 6807

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Instructions > Page 68

Voyager V6-3.0L VIN 3 (2000)

Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

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Radiator Cooling Fan Motor Relay: Diagnostic Aids

Intermittent and Poor Connections
INTERMITTENT AND POOR CONNECTIONS

Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay tocause a problem. Before condemning a component or wiring assembly, check the following items.-

Connectors are fully seated

- Spread terminals, or terminal push out

- Terminals in the wiring assembly are fully seated into the connector/component and locked into position

- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem

- Damaged connector/component casing exposing the item to dirt or moisture

- Wire insulation that has rubbed through causing a short to ground

- Some or all of the wiring strands broken inside of the insulation

- Wiring broken inside of the insulation

Troubleshooting Tests

Fig.6 Electrostatic Discharge Symbol

STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES

All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, complywith the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If itis not known whether the part is ESD sensitive, assume that it is.

1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding
across a seat, sitting down from a standing position, or walking a distance.

2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.3. When using a voltmeter, be sure to connect the ground lead first.4. Do not remove the part form it's protective packing until it is time to install the part.5. Before removing the part from it's package, ground the package to a known good ground on the vehicle.

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Voyager V6-3.0L VIN 3 (2000)

Fig.7 Testing For Voltage Potential

STANDARD PROCEDURE - TESTING FOR 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
appropriate test procedure.

STANDARD PROCEDURE - TESTING FOR CONTINUITY

1. Remove the fuse for the circuit being checked or, disconnect the battery.

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Instructions > Page 71

Voyager V6-3.0L VIN 3 (2000)

Fig.8 Testing For Continuity

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 apart and watch the voltmeter/test lamp.6 - 8 inches

4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness.

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.

Fig.9 Testing For Voltage Drop

STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP

Troubleshooting Tools

When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below.

Jumper Wire

This is a test wire used to connect 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 BATTERYFEED AND GROUND.

Voltmeter

Used to check for voltage on a circuit. 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 witha or greater impedance rating.10 mega-ohm

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Voyager V6-3.0L VIN 3 (2000)

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 voltage between the two points.

Ohmmeter

Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity.

CAUTION:

10 mega-ohm

Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meterwith a or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered upby the vehicle's electrical system can cause damage to the equipment and provide false readings.

Fig. 4 Probing Tool

Probing Tools

These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into theterminal being tested. Use the other end of the tool to insert the meter probe.

Troubleshooting Wiring Problems

When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check fornonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-onitems are not the cause of the problem.

1. Verify the problem.2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the
diagnosis will continue.

4. Isolate the problem area.5. Repair the problem.6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit.

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Radiator Cooling Fan Motor Relay: Description and Operation

DESCRIPTION

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Voyager V6-3.0L VIN 3 (2000)

8w-90-10

Radiator Fan Relay

The radiator fan relay is a solid state type and is located under the left front headlamp module.

OPERATION

(PCM) (PWM)

The solid state radiator fan relay is controlled by the Powertrain Control Module by way of a Pulse Width Modulated signal. The relay control circuit supplies a 12 volt signal to the PCM. The PCM then pulses the ground circuit to achieve fan on time. The relay provides avoltage to the fan motors which is proportional to the pulse width it receives from the PCM. The duty cycle ranges from 30 % for low speedoperation, then ramps up to 100 % for high speed operation. This fan control system provides infinitely variable fan speeds, allowing for improvedfan noise, A/C performance, better engine cooling, and additional vehicle power.

To control operation of the relay, the PCM looks at inputs from:-

Engine coolant temperature

- A/C pressure transducer

-

Ambient temperature from the Body Control Module (BCM)

- Vehicle speed

- Transmission oil temperature
The PCM uses these inputs to determine when the fan should operate and at what speed.