Circuit Testing Procedures - Non-Dtc-Based Diagnostics Chrysler Town & Country V рестайлинг

GENERAL WARNINGS

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

CIRCUIT FUNCTIONS

All circuits in the wiring diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the CIRCUIT IDENTIFICATION CODE CHART.

Note. This chart shows the main circuits only and does not show the secondary codes that may apply to some models.

CIRCUIT IDENTIFICATION CODE CHART

CIRCUIT INFORMATION

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

As an example, circuit A 2 18 LB/YL is decoded in the following manner

WIRE COLOR CODE CHART

TROUBLESHOOTING TOOLS

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

The voltmeter is used to measure the electrical pressure or the voltage difference between two points. A voltmeter reads available voltages such as battery voltage, generator output voltage, and voltage drop across a component or conductor. A high voltage drop may indicate a high resistance in the circuit. The voltmeter can be used to locate an open circuit and circuits with an unintentional ground. Observing polarity, always connect a voltmeter in parallel to the existing circuit. If the leads are reversed on a digital multimeter, a minus sign appears in the display.

The ohmmeter is used to measure the resistance of a component or the resistance between two points in a circuit in ohms, and to check a portion of the circuit for continuity. Some meters have a built-in tone to indicate that the circuit has continuity. No resistance indicates a short circuit or unintentional ground whereas resistance that is higher than specification indicates a high resistance in the circuit such as a loose, dirty or corroded connection, or a defective component. An "OL" reading means that the circuit or component had infinite resistance; an open circuit or defective component is indicated. Ohmmeters have an internal battery and must never be connected to a power circuit. Connecting an ohmmeter to a powered circuit causes the meter fuse to blow and can damage its dry cell battery. Ohmmeters can be connected into a circuit without regard to polarity, unless the circuit contains a diode. When using an ohmmeter, the component or portion of the circuit must be isolated from other components or branches to avoid false readings.

The 12-Volt test light when properly used, is one of the best and quickest pieces of test equipment available for troubleshooting 12-volt power systems. It's especially good for times when there are only two voltages, battery voltage and no voltage. For example, if you're checking to see if you have 12-volts on the Battery(+), the test light will immediately tell you if voltage is present or not.

With any test equipment, you should confirm that it's in good working order before you begin testing. For a test light, you have to have a voltage source. Connect the test light's ground clip to a good ground and touch it to a point where you believe that there is 12-volt supply. If the light doesn't light up, check the light by connecting it directly across the battery. Initially, make sure that you have the ground clip on the negative battery terminal. If you touch the probe to the positive terminal, the test light should light up. If it doesn't and the battery is not completely dead, the test light isn't working properly. The test light must be in proper working order before any circuit testing can occur.

The sole purpose of the jumper wire is to complete a circuit. It is nothing more than a suitable length of insulated wire with terminals or connectors on each end. Jumper wires may be bought or made with various sizes of wire and styles of terminals including alligator clips, spade lugs and pin plugs, and should include a fuse device of some type for circuit and component protection. A jumper wire is used to verify a faulty conductor by substituting a known good one. It is jumped across a suspicious conductor in the circuit. If the circuit works with the jumper, but not without, there is an open somewhere in the area being jumped. A jumper wire is ONLY used to bypass a faulty conductor (including switches and connectors). NEVER bypass a load device with a jumper wire. The circuit needs the resistance from the load device and shorting across it causes high current flow, which could damage other components.

Scheme 9

These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package (special tool #6807, Terminal Tools), and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe.

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 to cause a problem.

Before condemning a component or wiring assembly, check the following items

1. Connectors are fully seated

1. Spread terminals, or terminal push out

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

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

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

1. Wire insulation that has rubbed through causing a short to ground

1. Some or all of the wiring strands broken inside of the insulation

1. Wiring broken inside of the insulation

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 for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem.

Perform the following Six Step Diagnosis Process

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 appropriate 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 area.
6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit (Refer to the appropriate wiring diagrams).

Note. The Six Step Diagnosis Process used by Chrysler is a time proven process. The basic concepts of this process have been used by others for problem solving for many years. The successful application of this process requires a solid understanding of the conditions that affect each step, and when its time to advance to the next step. These conditions based on experience formulate what is known as "Best Practices".

Scheme 10

1. Turn the ignition off. Disconnect the wire harness connectors from the module and component for the circuit being tested. NOTE: Check connectors - Clean/repair as necessary. At this time, leave all in-line connectors connected. NOTE: Before testing any circuits, first verify the 12-volt test light is operating properly. Connect the 12-volt test light to battery ground or to any other known good ground. Touch the lead of the test light to Battery(+). If the test light is operational, it should illuminate brightly. Connect the 12-volt test light to a known good ground. Use the test light lead to carefully probe the Battery or Ignition Voltage circuit in the harness connector. First check with the ignition off, next check with the ignition on, and lastly check while cranking the engine. Does the test light illuminate brightly? Yes The circuit is not open at this time or the condition that originally caused the open may not be present at this time. Continue to monitor the test light and wiggle the wire harness and connectors to check for an intermittent open or excessive resistance condition. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the open could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply. No Repair the open in the circuit. Use the wiring diagram as a guide to trace the circuit and look for any in-line connectors where the open could occur. One method to help isolate the open is to disconnect any in-line connectors and measure the resistance from one side of the in-line connector to the matching component harness connector. If the open goes away, the open is on the other side of the in-line connector. If this is a fused circuit, make sure to inspect the fuse. If the fuse is open, check the circuit for a short to ground before installing a new fuse. The circuit may have a short to ground causing the fuse to open. This short to ground could be in the wire harness or in one of the components the circuit is supplying voltage to.

Scheme 11

1. Turn the ignition off. Disconnect the wire harness connectors from the module and component for the suspected circuit being shorted to ground. NOTE: Check connectors - Clean/repair as necessary. NOTE: Before measuring the resistance of any circuit, first measure the resistance between the two leads of the multimeter. Take this value and subtract it from the value recorded when measuring the resistance of the circuit being checked (The meter leads can add 0.5 ohm or more of total resistance). With the component wire harness connectors disconnected, use a meter set to measure Ohms (?), and measure the resistance between the circuit and a known good ground. Use the negative lead of the meter and touch a known good ground. Use the positive lead of the meter and carefully probe the circuit suspected of having the short. Is the resistance to ground below 10k ohms ? Yes Repair the short to ground. Use the wiring diagram as a guide to follow the path of the circuit. One method to help isolate the short is to disconnect any in-line connectors that the circuit being tested runs through and measure for the short again. If the short goes away, the short is on the other side of the in-line connector. No The circuit is not shorted to ground or the condition that originally caused the short may not be present at this time. Continue to measure the resistance, wiggle the wire harness and connectors while checking for an intermittent short. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply.

Scheme 12

The purpose for the following procedure is to demonstrate different methods of checking the voltage of a circuit. When diagnosing a DTC it might be necessary to verify that proper voltage is on a circuit or that a circuit is not shorted high. Below are four examples of checking the voltage in a circuit.

Scheme 13

Scheme 14

1. CHECKING FOR VOLTAGE USING A MULTIMETER NOTE: The connector displayed in the graphics are only an example. Turn the ignition off. Disconnect the wire harness connector of the component that is being tested. NOTE: Check connectors - Clean/repair as necessary. At this time leave all in-line connectors connected. Use a multimeter set to measure DC voltage. Connect the ground lead of the meter to a known good ground. Use the positive lead of the multimeter and probe the circuit that is being checked for voltage. Ignition on, engine not running. Is the voltage within specifications for this circuit? Yes The circuit is functioning properly or the condition that originally caused the open or short may not be present at this time. Continue to measure the voltage and wiggle the wire harness and connectors while checking for an intermittent open or short. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply. No Repair the open or short to ground in the circuit. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur. One method to help isolate the open or short is to disconnect any in-line connectors that the circuit being checked runs through and check for the voltage again. If the voltage is present, the open or short is on the other side of the in-line connector.
2. CHECKING FOR A SHORT TO BATTERY VOLTAGE USING A MULTIMETER Turn the ignition off. Disconnect the wire harness connectors of the components that contain the circuit that is suspected as having a short. NOTE: Check connectors - Clean/repair as necessary. At this time leave all in-line connectors connected. With all the component wire harness connectors disconnected, use a multimeter set to measure DC voltage. Connect the ground lead of the meter to a known good ground. Use the positive lead of the multimeter and probe the circuit that is being checked for a short. Is there any voltage present? Yes Repair the short to battery voltage. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur. One method to help isolate the short is to disconnect any in-line connectors that the circuit being checked runs through and measure for the short again. If the short goes away, the short is on the other side of the in-line connector. No The circuit is not shorted to voltage or the condition that originally caused the short may not be present at this time. Continue to measure the voltage and wiggle the wire harness to check for an intermittent short. NOTE: By disconnecting the wire harness connectors you may have eliminated the source of the voltage causing the short. Use the wiring diagram as a guide, check to see if there are any battery circuits in the same wire harness as the circuit you are testing. It is necessary to check for a short to those circuits using an ohmmeter, perform the CHECK FOR A SHORT BETWEEN MULTIPLE CIRCUITS diagnostic procedure. Refer to «STANDARD PROCEDURE»(/chrysler/town-country/v-2010-2016/remont/body-electrical/#circuit-testing-procedures-non-dtc-based-diagnostics) . Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply.
3. CHECKING FOR A SHORT TO IGNITION VOLTAGE USING A MULTIMETER Turn the ignition off. Disconnect the wire harness connectors of all components that contain the circuits that are suspected as being shorted. At this time leave all in-line connectors connected. With all the component wire harness connectors disconnected, use a multimeter set to measure DC voltage. Connect the ground lead of the meter to a known good ground. Use the positive lead of the multimeter and probe the circuit suspected of having the short. Ignition on, engine not running. Is any voltage present? Yes Repair the short to ignition voltage. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur. One method to help isolate the short is to disconnect any in-line connectors that the circuit being checked runs through and check for the short again. If the short goes away, the short is on the other side of the in-line connector. No The circuit is not shorted to voltage or the condition that originally caused the short may not be present at this time. Continue to measure the voltage and wiggle the wire harness to check for an intermittent short. NOTE: By disconnecting the wire harness connectors you may have eliminated the source of the voltage causing the short. Use the wiring diagram as a guide, check to see if there are any battery circuits in the same wire harness as the circuit you are testing. It is necessary to check for a short to those circuits using an ohmmeter and perform the CHECK FOR A SHORT BETWEEN MULTIPLE CIRCUITS diagnostic procedure. Refer to «STANDARD PROCEDURE»(/chrysler/town-country/v-2010-2016/remont/body-electrical/#circuit-testing-procedures-non-dtc-based-diagnostics) . Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply.
4. CHECKING FOR A SHORT TO VOLTAGE USING A 12-VOLT TEST LIGHT Turn the ignition off. Disconnect the wire harness connectors of all components that contain the circuits that are suspected of having the short. NOTE: Check connectors - Clean/repair as necessary. At this time leave all in-line connectors connected. NOTE: Before testing any circuits, first verify the 12-volt test light is operating properly. Connect the 12-volt test light to battery ground or to any other known good ground. Touch the lead of the test light to Battery(+). If the test light is operational, it should illuminate brightly. Connect the 12-volt test light to a known good ground. Use the lead of the test light and carefully probe the circuit suspected of having the short. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. First, check with the ignition off, next with the ignition on, and lastly while cranking the engine. Does the test light illuminate brightly? Yes Repair the short to voltage. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur. One method to help isolate the short is to disconnect any in-line connectors that the circuit being checked runs through and check for the short again. If the short goes away, the short is on the other side of the in-line connector. No The circuit is not shorted to voltage or the condition that originally caused the short may not be present at this time. Continue to measure the resistance and wiggle the wire harness to check for an intermittent short. NOTE: By disconnecting the wire harness connectors you may have eliminated the source of the voltage causing the short. Use the wiring diagram as a guide, check to see if there are any battery circuits in the same wire harness as the circuit you are testing. It is necessary to check for a short to those circuits using an ohmmeter and perform the CHECK FOR A SHORT BETWEEN MULTIPLE CIRCUITS diagnostic procedure. Refer to «STANDARD PROCEDURE»(/chrysler/town-country/v-2010-2016/remont/body-electrical/#circuit-testing-procedures-non-dtc-based-diagnostics) . Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related component and wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply.

Scheme 15

1. Turn the ignition off. Disconnect the wire harness connectors of the components that contain the ground circuit suspected of containing excessive resistance. NOTE: Check connectors - Clean/repair as necessary. At this time leave all in-line connectors connected. NOTE: Before testing any circuits, first verify the 12-volt test light is operating properly. Connect the 12-volt test light to battery ground or to any other known good ground. Touch the lead of the test light to Battery(+). If the test light is operational, it should illuminate brightly. With all the component wire harness connectors disconnected, connect the 12-volt test light to Battery(+). Use the test light lead to lightly probe the ground circuit in the harness connector. Does the test light illuminate brightly? Yes The suspected ground circuit is not open or the condition that originally caused the open or excessive resistance is not present at this time. Another way to check for an open would be to use an ohmmeter and measure the resistance of the ground circuit. While continuing to measure the resistance of the circuit, wiggle the wire harness and connectors to check for an intermittent open or poor connection. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the open could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply. No Repair the open in the ground circuit. Use the wiring diagram as a guide to trace the circuit and look for any in-line connectors where the open could occur. One method to help isolate the open is to disconnect any in-line connectors and measure the resistance from one side of the in-line connector to the matching component harness connector. If the open goes away, the open is on the other side of the in-line connector.

Scheme 16

1. Turn the ignition off. Disconnect the wire harness connectors of the components that contain the circuits that are suspected of being shorted together. NOTE: Check connectors - Clean/repair as necessary. At this time leave all in-line connectors connected. NOTE: Before measuring the resistance of any circuit, first measure the resistance between the two leads of the multimeter. Take this value and subtract it from the value recorded when measuring the resistance of the circuit being checked (The meter leads can add 0.5 ohm or more of total resistance). With all the component wire harness connectors disconnected, use a multimeter set to Ohms (?), and measure the resistance between the applicable circuits in one of the harness connectors. Use one lead of the multimeter and carefully probe the circuit suspected of being shorted. Use the other lead of the meter and one at a time, carefully probe the other circuits in the harness connector. Is the resistance below 10k ohms when probing any two circuits? Yes Repair the short between the circuits. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur. One method to help isolate the short is to disconnect any in-line connectors that the circuit being tested runs through and measure for the short again. If the short goes away, the short is on the other side of the in-line connector. No The circuit is not shorted or the condition that originally caused the short may not be present at this time. Continue to measure the resistance and wiggle the wire harness and connectors while checking for an intermittent short. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the short could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply.

DIAGNOSTIC TEST

1. Turn the ignition off. Disconnect the Negative Battery cable (ground). Using a multimeter, set the multimeter leads up to properly measure Amperage. Connect the ground lead that is plugged into the COM port of the multimeter to the Negative Battery cable. Connect the other lead of the multimeter that is plugged into the Amp port of the multimeter to the negative battery post/terminal. CAUTION: Do not crank the engine or turn on any accessories that may draw more than 10 Amps. You may open the protective fuse in the multimeter. NOTE: To get a more accurate current draw reading, wait 20 minutes to make sure all modules have powered down before continuing. Some modules may stay powered up longer than others. While monitoring the amperage reading, remove a fuse and see if the amperage drops. NOTE: Only remove one fuse at a time until the cause of the voltage draw is determined. If the amperage does not drop, install the fuse you just removed and remove the next fuse. Does the amperage drop to between 0.02 to 0.04 of an Amp when removing any fuses? Yes Use the wiring diagram as a guide to help indicate what components or modules are powered by the fuse. At this point you can install the fuse and begin disconnecting the components powered by the fuse. When the amperage drops after disconnecting a component this will indicate which component is at fault. It is important to know how long some modules are designed to remain awake. You don't want to replace a component that is operating normally. No The condition that originally caused the draw may not be present at this time. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded ground terminals. Perform any Technical Service Bulletins (TSBs) that may apply.

Scheme 17

1. NOTE: The preferred method of checking for an open ground circuit is to perform the "CHECK A GROUND CIRCUIT FOR AN OPEN USING A 12-VOLT TEST LIGHT" diagnostic procedure. Turn the ignition off. Disconnect the wire harness connectors of the components that contain the circuit suspected of being open. NOTE: Check connectors - Clean/repair as necessary. At this time leave all in-line connectors connected. NOTE: Before measuring the resistance of any circuit, first measure the resistance between the two leads of the multimeter. Take this value and subtract it from the value recorded when measuring the resistance of the circuit being checked (The meter leads can add 0.5 ohm or more of total resistance). With the component wire harness connectors disconnected, use a multimeter set to Ohms (?), and measure the resistance of the circuit. Use one lead of the meter and probe the circuit in one harness connector. Use the other lead of the meter and probe the same circuit in the other harness connector. Is the resistance in the circuit below 20k ohms? Yes The circuit does not contain any excessive resistance or the condition that originally caused the excessive resistance may not be present at this time. Continue to measure the resistance of the circuit, wiggle the wire harness and connectors to check for an intermittent open or poor connection. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the open could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply. No Repair the excessive resistance in the circuit between the two wire harness connectors. Using the wiring diagram as a guide, trace the circuit and check for any in-line connectors where the open or excessive resistance could occur. One method to help isolate the open is to disconnect any in-line connectors and measure the resistance from one side of the in-line connector to the matching component harness connector. If the open or excessive resistance is not present, the open or excessive resistance is on the other side of the in-line connector.

Scheme 18

Scheme 19

1. MEASURE THE VOLTAGE BETWEEN THE 5-VOLT SUPPLY CIRCUIT AND GROUND Turn the ignition off. Disconnect the sensor harness connector. NOTE: Check connectors - Clean/repair as necessary. Turn the ignition on. Set the multimeter to measure DC voltage. Connect the negative lead of the multimeter to a known good ground. With the positive lead of the multimeter, carefully probe the 5-volt supply circuit. Is the voltage between 4.7 and 5.2 volts? Yes Go To 2 No Check the 5-volt supply circuit for an open or short to ground. For further assistance, perform the appropriate Sensor Reference Voltage DTC diagnostic procedure. Refer to the «DTC INDEX»(/chrysler/town-country/v-2010-2016/remont/dtc-index/#dtc-index) article.
2. MEASURE THE VOLTAGE BETWEEN THE 5-VOLT SUPPLY AND SENSOR GROUND CIRCUIT With the multimeter set to measure DC voltage. Move the negative lead of the multimeter to carefully probe the sensor ground or sensor return circuit in the harness connector. With the positive lead of the multimeter, carefully probe the 5-volt supply circuit. Is the voltage between 4.7 and 5.2 volts? Yes At this time the 5-volt supply and sensor ground circuit are working properly. Continue to measure the voltage between the wires, wiggle the wire harness and connectors while checking for an intermittent condition. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the open could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply. No Repair the open or excessive resistance in the Sensor Ground (Sensor Return) circuit.

Scheme 20

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

Perform the following procedure when handling ESD sensitive components

1. Always touch a known good ground before handling the component. This should be repeated while handling the component 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 component, 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 component from its protective packing until it is time to install the component.
5. Before removing the component from its package, ground the package to a known good ground on the vehicle.

THEORY OF OPERATION

Voltage drop is the reduction in voltage in an electrical circuit between the voltage source and load components. The wires and connectors of a circuit should contain almost no resistance and all the voltage should be consumed through the load. The "load" is the component using the power, such as a light, starter, or blower motor. If a circuit has excessive resistance, it prevents the wire from carrying sufficient current under high load conditions. A voltage drop test is an effective way to locate excessive resistance in connections and circuits.

To perform a voltage drop test, a Digital Volt Ohm Meter (DVOM) is used to measure the voltage drop across a live circuit or connection while it is under the load. If the circuit or connection being tested has excessive resistance, the DVOM will measure the voltage that the resistance is using. Little or no voltage drop should be read, ideally less than 0.2 of a volt , anything greater indicates excessive resistance and the circuit or connection should be inspected for cleaning or repair.

Scheme 21

1. TESTING FOR VOLTAGE DROP Turn the ignition off. Use the wiring diagram as a guide, trace the circuit being tested and locate the components related to the circuit. Set the multimeter to measure DC voltage. Carefully back probe the two component harness connectors of the circuit being tested. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If you are testing the starting circuit, disable the engine so the engine does not start. Crank the engine for five seconds if you are testing the starting circuit and monitor the multimeter voltage reading. For circuits that don't require the engine running, turn the ignition on. For circuits that require the engine running, start the engine. NOTE: If the circuit you are checking needs to be turned on, such as Blower Motor or a Lamp, do so now. Monitor the voltage reading. The voltmeter will show the difference in voltage between the two points. Is the voltage less than 0.2 of a Volt? Yes At this time the circuit is functioning properly. Continue to measure the voltage between the components and wiggle the wire harness and connectors while checking for an intermittent condition. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors where the excessive resistance could occur intermittently. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply. No Repair the excessive resistance in the circuit. Use the wiring diagram as a guide to trace the circuit and look for any in-line connectors where the excessive resistance may occur. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related wire harness connectors. Perform any Technical Service Bulletins (TSBs) that may apply.

WIRE SPLICING

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Remove 13 millimeters (0.50 inch) of insulation from each wire that needs to be spliced.
2. Place a piece of adhesive sealant-lined heat shrink tubing (Part Number 04778570 or equivalent) over the wire on one side of the splice. Be certain the length of tubing will be sufficient to cover and seal the entire repair area.
3. Place the strands of the wires being spliced so that they are overlapping each other within the splice band (1).
4. Using a crimping tool (1) (MOPAR Part Number 05019912AA, Miller Special Tool Number (special tool #10042, Crimper, Wire/Terminal) or equivalent) crimp the splice band and wires together securely. CAUTION: Never use acid core solder for electrical wiring repairs.
5. Using Rosin Core type solder (1) only and a suitable soldering iron (3), solder the wire and splice band connection (2) together.
6. Center the heat shrink tubing (2) over the splice joint repair and heat using a suitable heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) begins to ooze out of both ends of the tubing.

Scheme 26

Scheme 27

Scheme 28

1. Disconnect battery.
2. Release Connector Lock (2).
3. Disconnect the connector (3) being repaired from its mating half/component.
4. Remove the dress cover (if applicable) (1). 1 - Secondary Terminal Lock
5. Release the Secondary Terminal Lock, if required (1). 1 - TYPICAL CONNECTOR 2 - PICK FROM TERMINAL REMOVER KIT 6680 OR 8197A 3 - APEX CONNECTOR 4 - PICK FROM TERMINAL REMOVER KIT 6680 OR 8197A 5 - AUGAT CONNECTOR 6 - ELECTRICAL REMOVER 6932 7 - MOLEX CONNECTOR 8 - PICK FROM TERMINAL REMOVER KIT 8197A 9 - THOMAS AND BETTS CONNECTOR 10 - TERMINAL REMOVER 6934 11 - TYCO CONNECTOR 12 - ELECTRICAL TERMINAL REMOVER 8638
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.

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). Refer to «WIRE SPLICING»(/chrysler/town-country/v-2010-2016/remont/body-electrical/#circuit-testing-procedures-non-dtc-based-diagnostics__wire-splicing) .
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 1-1/2 inches behind the connector and 2 inches past the repair.
7. Connect battery and test all affected systems.

See also:
• DTC INDEX
• STANDARD PROCEDURE
• WIRE SPLICING