Chrysler / Dodge Minivan Service Manual 2011-2014 Model Year Main: Local: Fax: (800) 956-6668 (952) 890-7851 (952) 808-2775 Your Life. Your Ride. 6591 W. Hwy 13 Savage, MN 55378 www.rollxvans.
Chrysler / Dodge Minivan 2011-2014 Model Year Service Manual #13315-004 June 2014
TaBle of conTenTS Important Item Locations ...................................................................................................................... 1 Battery Information - General ............................................................................................................... 6 Battery Information - Draw Test Procedure .......................................................................................... 8 Rollx Vans Door (Motor Bar) - Troubleshooting ......................
TaBle of conTenTS Folding Ramp - Replacement Parts ................................................................................................... 46 Folding Ramp - Motor Install / Removal and Adjustment ................................................................... 49 Rear Heat & Air................................................................................................................................... 51 Remote System - Troubleshooting ..................................................
iMPorTanT iTeM locaTionS OEM Main Wire Harness (Floor Along Driver’s Side) Rollx Vans Main Wire Harness (Ceiling Along Passenger’s Side) Rear Heat & A/C Front Connections OTC Main Fuse ITF Ramp Access Panel ITF Ramp Override Switch Neutral Safety Signal Splice Rear Heat and Air Unit Driver Seat Detector Power Seat Connector(s) OTC fuse panel (Under Glove Box) Wing Window Interface (after 4/15/2014) OTC Remote Receiver Passenger Seat Detetector Door Detector (after 4/15/2014) (after 8/26/2013) Po
iMPorTanT iTeM locaTionS Main Fuse (Engine Compartment) 6way Seat Fuse (40 Amp) (If Equipped) OTC Remote Receiver Rear Heat & A/C Unit Main OTC Fuse (40 Amp) OEM Wire Harness Rollx Vans Main Wire Harness Runs Along Driver’s Side Floor Runs Along Passenger’s Side Ceiling Passenger Sliding Door Open Switch OTC Fuse Panel (Under Glove Box - Must Pull Back Fabric) Power Tie Down (If Equipped) Used Before 8/26/2013 Rollx Vans Remote 6way controller (If Equipped) Ignition Hot Neutral Safety Vans are e
iMPorTanT iTeM locaTionS OTC Relay Board (Behind Rear Passenger Quarter Panel) ITF Ramp Access Plate Rear AC (Rear Connections) (Behind Rear Right Tire) Rear Heat (Rear Connections) (Right Rear Tire) Rear Heat & A/C (Front Connections) (Under Passenger’s Side Front Seat Area) Kneeler and One Touch Controller Rear Heat OTC Board Rear A/C Kneeler Page 3 Universal Door Detector Used After 8/26/2013 (behind panel)
iMPorTanT iTeM locaTionS ITF Ramp Override Switch Neutral Safety Signal NOTE: Rollx Vans taps into the “TRS T3 SIGNAL” at the “TRANSMISSION SOLENOID PRESSURE SWITCH” to pick up the Neutral Safety signal *See OTC WIRING for diagram Passenger’s Door Detector (Built After 4/15/2014) (On Passenger’s C-Pillar) Wing Window Interface (Built After 4/14/2014) (Behind Rear Heat & Air Unit) OTC Remote Programming Switch Driver’s Power Seat Connector (Passenger’s Same) Page 4
iMPorTanT iTeM locaTionS Rollx Vans Ignition Hot & Neutral Safety Board Wiring 2008-2013 Chrysler Minivans (built after 5/28/2009) BK (8 GA.) - + 40A RD (8 GA.) FUSE RD (8 GA.
BaTTerY inforMaTion - general The following procedure should be used to test the current draw from any battery used in our vans. 1) Insure the battery is fully charged. 2) Remove the key from the ignition switch. 3) Close all the doors including the sliding doors and the rear tailgate. 4) Close all the windows including the rear vent windows. 5) Remove the negative (Black) cable from the battery and move it to a safe location away from both the positive (Red) and negative terminals of the battery.
BaTTerY inforMaTion - general 14) The Multimeter should now show a reading. Keep your eye on the meter and watch the draw. A typical van can have from 18 to 28 computer modules in it. They are all woke up when power was applied to the van by attaching your meter probes. As you watch the current reading you will note that it will start to fall. This happens as the computers in the van decide they are not needed and put themselves to sleep.
BaTTerY inforMaTion - draW TeST Procedure This picture shows a complete setup for a Draw Test: Note the black probe attached to the negative terminal and the red probe attached to the negative battery cable. This picture shows a typical multimeter. Note the current range switch settings and current probe jack markings are all in yellow for uA (Microamps), mA (Milliamps and A (Amps). Also note that the meter has two Jacks for current measurement, “20A” and “uA/mA”.
rollX vanS door (MoTor Bar) TrouBle ShooTing Symptom Door does not operate. Possible Cause Front passenger door is locked. Switch is stuck. Blown fuse. Manual release handle is not engaged. Door will open, but ramp will not deploy. Door will open, but not close or door will "jump" closed. Door "ratchets" when operating (make sure kneeler is off). 3/26/2013 Door open limit switch needs adjustment. Remedy Unlock front passenger door. Make sure all user switches are not stuck.
Page 10 2 3 4 5 1 1 1 1 Item Qty. 1 1 1 1 1 1 15 8 11 17 4 10 9 Description Part # DOOR BAR ASM (INCLUDES THE 3 FOLLOWING) 10026ASM MTR BAR DOOR OPENER (RACK AND ASSEMBLY) 10026 WIRE HARNESS 5.5" FOR 310-1059 MTR 12V 10NM 10MM DOUBLE 210-1011 GEAR RACK (SPECIFY LONG OR SHORT)* 10026-4 LONG BAR 1126318 3/8 X 1 STRIP ARM BAR (FOR MOTOR BAR) 10026-22 WIRE HARNESS 5.
oeM PoWer door TrouBleShooTing Note: In order to disable the OEM door from closing when the ramp is out, Rollx Vans interupts Chryler’s CAN BUS circuit to prevent the door from getting any signal to close. The Scan tool will read a “No Communication with the Right Rear Door Module” everytime the system deploys the ramp. This is a normal trouble code and is to be excpected. Symptom Passenger sliding door does NOT OPEN with interior Rollx Vans user button.
door ModificaTionS Door extension kits part numbers and descriptions Inner Door Skin (Extension) Driver Side - #B08180-D5 Passenger Side - #B08180-P5 -B08180-D5-KIT-ITF Door skin svc kit itf dr -B08180-D5-KIT-FO door skin svc kit fo dr -B08180-P5-KIT-ITF Door skin svs kit itf pass -B08180-P5-KIT-FO Door skin svs kit fo pass #10277 - Rivets (9 per Door) Outer Sliding Door Current #B08180-DP6 - L BRKT DOOR SKIN DR/PASS 08 Before 10/20/2008 #10503 - 1”X 1” 14GA ROLLED ANGLE #B08033 ‘08 LOWER DOOR ARM (Spa
door ModificaTionS DOOR OPEN SWITCH ASSEMBLY - #05089-003 Built Before 8/26/2013 1/4-20X1/2” Hex Bolt #0115001 M+ ZOO FHSCS 1/4-20X1/2 ZB #94222 DOOR TRACK EXT BKT LOWR 08 #B08032 (#B08032-1 Vans Started after 7/21/2010) DOOR TRACK EXT BKT LOWR 08 ASM #B08032ASM (#B08032-1ASM Vans Started after 7/21/2010) (Includes Switch, Wire Harness, and Bracket) SNAKE CONNECT BLOCK SLIDE ARM #B08050 (Not Shown) Door track kits and descriptions include OEM track and door open switch bracket B08059asm-dr - Door tr
eXhauST SYSTeM OEM Catalytic Converter / O2 Sensor Rollx Vans Exhaust 3.3L & 3.8L #B08200-SS 4.0L #B08202 3.6L #B11200-SS Rollx Vans Weld OEM Hanger Rollx Vans begins their exhaust from the OEM Catalytic Converter (Rollx Vans does not modify the OEM Catalytic Converter or OEM 02 Sensor). Rollx Vans Exhaust is welded to the OEM Catalytic Converter and runs down the passenger side of the van. Rollx Vans reuses the OEM Hangers to support the exhaust.
eXhauST SYSTeM Rollx Vans Exhaust #B08201-SS Rollx Vans Weld OEM Muffler and Tailpipe Rollx Vans Exhaust continues over the rear axle and is welded to the OEM Muffler and Tailpipe. Rollx Vans eliminates the OEM Resonator.
eXTerior / van diMenSionS #B08180-P = Passenger Side #B08180-D = Driver Side (Chrysler Vans Only) #B08180-P4 #B08180-D4 (Dodge Vans Only) #B08180-P4D #B08180-D4D (Before 12/2/08) #B08180-P3 #B08180-D3 (Before 12/2/08) #B08180-P2 #B08180-D2 (After 12/2/08) #B08180-P3.2 #B08180-D3.2 (After 12/2/08) #B08180-P2.2 #B08180-D2.2 #B08180-P1 #B08180-D1 When replacing either of these ground effects on a 2008 Chrysler van built before 12/2/08.
fuel SYSTeM 2011-2014 Chrysler Town & Country / Dodge Grand Caravan (3.
Page 18 0° OET 15 Rollx Vans Charcoal Canister Vent Hose (5/8”) Part #10929-00834 (FUEL LINE 5/8”-R7) 53 inches OEM Quick Disconnect (5/8”) OEM Charcoal Canister Rollx Vans Fuel Fill Vent Hose (5/16”) Part #H-211 (5/16” HIGH PRESSURE HOSE-R9) 37 inches OEM Quick Disconnect (5/16”) OEM Fuel Fill Vent Metal Line OEM Filler Neck Top (Gas Cap) Rollx Vans Main Fuel Metal Line (5/16”) Part #126299 (5/16”X028/X13' FUSION) 45° OET 17 90° OET 15 OEM Fuel Tank 90° Clamp #10 OEM Fuel Pump / OEM Fuel Filt
fuel SYSTeM OEM Fuel Filler Neck (Gas Cap) OEM Fuel Fill Neck OEM Fuel Fill Vent Line Rollx Vans Fill Neck Extension #B08103 (Aluminized Steel Tubing) Rollx Vans Fuel Fill Neck Assembly #B08103ASM OEM Quick Disconnect with Rollx Vans Clamp #OET 1315 (5/16”) Rollx Vans Fuel Fill Vent Hose #H-211 (5/16” Fuel Injection Hose,SAE 30R9, Goodyear) Rollx Vans welds a Fill Neck Extension onto OEM Fuel Fill Neck to extend the OEM Fuel Fill Neck to the OEM Fill Neck Hose that attaches to the tank.
fuel SYSTeM Rollx Vans Main Fuel Hose Part #H-212 (3/8” Fuel Injection Hose,SAE 30R9,180 PSI,WP, CARB #c-u-06-002, Gates Corp.
fuel SYSTeM A) Rollx Vans routes the Rollx Vans Main Fuel Metal Line (5/16”) under the driver’s side of the van using P-Clamps to secure. B) The Rollx Vans Main Fuel Metal Line (5/16”) is routed up the rear z, flared and attached to OEM Quick Disconnect. C) The Rollx Vans Main Fuel Metal Line (5/16”) is routed up under the engine compartment, flared and attached to OEM Quick Disconnect.
fuel SYSTeM A) Rollx Vans runs the Rollx Vans Canister Vent Metal Line (3/8”) under the passenger side of the van using P-Clamps to secure. B) The Rollx Vans Canister Vent Metal Line (3/8”) is routed up under the engine compartment, flared and attached to OEM Quick Disconnect. C) The Rollx Vans Canister Vent Metal Line (3/8”) is routed up the rear z, flared and attached to OEM Quick Disconnect.
fronT SuSPenSion Front Strut Mounting Bolts #B08001ASM BOLTS: 5/16” -18 x 1” (QTY 6) #0115055 WASHERS: 1/4” ZINC FLAT(QTY 6) #1133004 LOCK WASHERS: 5/16” (QTY 6) #1133892 Strut Collar Assembly #B08001ASM *Reuse OEM strut collar nuts to fasten collar to strut.
rear SuSPenSion Vans Built Prior to 1-2-2013 COIL SPACER ON BOTTOM SERVICE KIT #R0046 Coil Spacer Coil Spacer Vans Built After 1-2-2013 SNUBBER EXTENSION ON TOP Traction Bar Spacers B08065 Snubber Extension Assembly p.n. B08055ASM Shock Absorber Brake line bracket B08068ASM-DR Brake line bracket B08068ASM-PS Trailing Arm BOLTS: (QTY 4) M10-1.
engine MounTing (cradle droP) BOLTS: BOLTS: M10-1.50 x 70mm (QTY 3) #0153994 M12-1.50 x 70mm (QTY 2) #38503 WASHERS: WASHERS: 3/8” ZINC FLAT(QTY 3) #1133008 1/2” ZINC FLAT(QTY 2) #1133012 1” Motor Mounts N05010 (QTY 5) Left Side Engine Mount Right Side Engine Mount 2.5” Motor Mount N05011 (QTY 5) Front Engine Mount Left Crossmember Bracket (Right side same) OEM Isolator bolt #4721 746AB (QTY 1) BOLTS: M12-1.75 x 50mm (QTY 4) #0122055 WASHERS: 3/8” ZINC FLAT(QTY 4) #1133012 BOLTS: M14-2.
TorQue SPecificaTionS Location Front Suspension Rear Suspension Engine & Cradle Mounting Torque Specifications Item Wheel nuts Camber Bolts Stabilizer Bar Link Nuts Strut Collar-to-Body Strut Collar-to-Strut Wheel nuts Trailing Arm Bracket-to Body Bolts Trailing Arm Pivot Thru-Bolts Traction Bar To Axle Bolts Shock Absorber Upper Mounting Bolts Shock Absorber Lower Mounting Bolts Front Engine Mount Right Side Engine Mount Left Side Engine Mount Left & Right Cradle Mounts Left & Right Cross Member Bracke
inTerior CLIP IN SEAT BASE COVERS #B08070-1 FOLDOUT RAMP ROLLER ASM (NOT SHOWN, FOLDOUT RAMP ONLY) BRACKET STABILIZER, 2008 - #F08018 ROLLERS CUSHIONED - #22875T11 L-TRACK 12 HOLE #10015-1 L TRACK 5 HOLE - #10006 L TRACK 3 HOLE (FRONT) #10016 L-TRACK 4-(FRONT) #Fe200763 DOG BONE COVERS #B2205-1 DOOR PANEL INTERIOR DRIVER #B8802-1 PASSENGER #B8803-1 B PILLAR INTERIOR DRIVER #B8800-1 PASSENGER #B8801-1 Wheel Well Cover Driver #B8808-1 Passenger #B8807-1 Interior Wire Cover #B8806-1 (may need to be pai
inTerior SEATBELT PASS, FEMALE, MED. SLATE PART #1GX881D5AA SEATBELT PASS. FEMALE, DK. SLATE PART #1GX881S3AA CLIP IN FOOTREST11 IN.
Kneeler TrouBleShooTing Symptom Possible Cause Kneel on / off switch is turned OFF. Remedy Turn kneel switch to the ON position. Van does NOT LOWER to ground while door is opening after Rollx Vans user button is pressed. Kneel motor or Broken Chain Review display board. Turn kneel switch to the OFF position and press OTC reset button. Operate without kneel option enables. Contact customer service. After van is lowered to ground the kneeler makes a loud ratcheting sound.
Qty. 1 2 1 1.
one Touch SYSTeM TrouBleShooTing Important: If OTC Board is removed, the OEM System will not operate normally unless the CAN Bus Shunt is installed. The shunt is attached to the wire harness behind the OTC board. See OTC Wiring Diagram for more information. Symptom Remedy Check that OTC ON/OFF switch is on. The power toggle switch is on the actual board. No power to One Touch Controller (OTC). Ensure the connections on the back of the OTC board are tight.
one Touch SYSTeM overvieW The Rollx Vans One Touch Controller, known as the OTC, is a Single Board Computer specifically designed for the Rollx Vans system. The OTC system was designed to be independent to the operation of the Chrysler computer system.
one Touch SYSTeM overvieW INPUTS KNEEL DISABLE SWITCH (Violet wire) Allows the user to enable (the “I” position) or disable (the “O” position) the kneeling system. There is no display for this input. OTC CONTROLLER POWER (2 White/Red wires) Supplies power to the OTC Board USER SWITCH INPUT (Blue wire) Active while any Rollx Vans user button or Rollx Vans remote is pressed. NEUTRAL INPUT (Green wire) Indicates the status of the gear shifter. When active, the van is either in neutral or park.
ESC ESC Page 34 DOWN ENTER Scrolls Last Error Kneel Down ESC UP ENTER START Rollx Vans Idle Hardware Version V-X.
one Touch SYSTeM - v8.0 advanced inTerface - SeTuP Options within Setup Setup View Data Log START Password Good View the past 30 errors recorded. Hit enter to view Error Details. UP ENTER ESC DOWN Setup Data Logger Mode Select “Log All Mode” or “Log Error Only Mode” to decide which type of errors to record. Default is “Log Error Only Mode”. Setup Engineering Setup Cycle Counters Displays the number of Open and Close cycles. Setup Kneeler Select if Kneel System installed or not.
one Touch SYSTeM - v8.0 advanced inTerface - deBugger How to Use Debugger (Output Test Mode) START Use extreme caution when using the Output Test Mode. The Output Test Modes sends the signal directly to the OTC Relay Board which results in power going to the called motor. No safeties are in place (ie. The Ramp Down will operate the ramp regardless if the door is open or closed. Output Test Mode UP ENTER ESC Output Test Mode Ramp Down Relay should click and ramp should go out.
one Touch SYSTeM - v8.0 advanced inTerface - deBugger How to Use Debugger (Input Test Mode) START Input Test Mode UP ENTER ESC The Input Test mode is very useful for testing the various limit switches the systems requires. To operate: 1) Select a Limit Switch (Input) you would like to test from the list below. 2) Notice if the Switch is “On” or “Off” when it is suppose to be. The audible beeps let you test the switch by hand without looking at the OTC Board.
one Touch SYSTeM - v8.0 error codeS For information about OTC Interface and how to use the Debugger, please refer to 'One Touch System - v8.0 Advanced Interace' section. Remember, in Input Test Mode, double beeps indicate the switch is on or activated and single beeps indicate that it is not. Also refer to the 'One Touch System - Relay Board Troubleshooting' for more information about the Relay Board, its Overide Switches and LED Indicator Lights.
one Touch SYSTeM - v8.0 error codeS Code Error 18 - Ramp Obstacle Detection Error Diagnostic Tests Check Error Log for multiple Obstactle Detection Errors. If there are many, raise the level in Setup. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. 1) Check Ramp Up [Limit Switch] by operating the ramp with Power Overide Switch (ITF Ramp) or manually raising (Folding Ramp).
one Touch SYSTeM - v8.0 error codeS Code Error 28 - Door Watchdog Error Diagnostic Tests Operate the OEM Door with the OEM B-Pillar Switch to determine of OEM Door is functioning properly. Input Test Place OTC in Debug - Input Test Mode to verify limits operate correctly. 1) Check Door Open (Rollx Vans Door Open Switch), by opening door all the way in Door Open. 2) Check Door Close (OEM Door Ajar Switch), by close door all the way in Door Close.
one Touch SYSTeM - relaY Board TrouBleShooTing RELAY BD OTC VERSION 2 P.N. 08044-003 ORDER #OTCV8 RELAY BD OUTPUTS Run to the Kneeler and Ramp Motors INPUTS Run from the OTC Control Board LED Indicator Lights Manual push button test switches *Pressing the switches should operate each function as shown on the board as long as the board is working properly. Remember, in order to run the ramp, the Ramp Enable must also be pressed at the same time.
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in The floor TrouBleShooTing Symptom Possible Cause Remedy Door open limit switch is not being activated. When a Open Cycle starts, the OTC will send a command to the Chrysler System to unlock the doors. It then sends a second command to the Chrysler System to open the Right Side Sliding Door. The OTC Computer then waits two seconds and checks the Door Closed Limit Switch. If it finds it still indicates the door is closed, it assumes that a person (or and obstacle) stopped the door opening sequence.
Page 44 17 18 19 20 21 21a 22 23 24 26 27 28 30 31 32 33 34 35 36 37 38 39 16 8 4 1 2 1 1 1 1 1 2 1 1 1 4 4 2 4 2 1 1 1 1 1 1 2 37 20 21a N05021G-F N05021G-B N08025-11 N08026-11 32 34 1107632 N1-N1DXLA N005001ASM 1173912 N05017ASM N05016ASM B08032ASM 05089-002 92510A351 2483K18 N05003ASM CHRLCL035 24412 10929-02112 1133004 N05049 97517A130 N05048 33 21 26 30 3 28 1 3/8 NYLON FLAT WASHER ROLLER, ITF RAMP PLATE RAMP ITF ASM 5/16-18X2 S/S FHSCS TRACK FLOOR PLATE FRONT ASM TRACK FLOOR PLATE REA
folding raMP TrouBleShooTing Symptom Ramp will NOT DEPLOY after door opens automatically. Ramp will NOT STOW automatically. Possible Cause Remedy Ramp fuse or circuit breaker is blown. Press Rollx Vans user button again to unkneel van and close door. Reset circuit breaker or check ramp fuse and replace if needed with 15 amp glass fuse located in glove box. Door open limit switch is not being activated. When a Open Cycle starts, the OTC will send a command to the Chrysler System to unlock the doors.
Page 46 Item 1 2 3 4 5 6 7 8 9 10 11 12 11 2 3 8 10 9 Description MOTOR RAMP (Does not include connector (OTC only) CAM FOR PICK UP ARM ALUM #8-32X1/4 CUP POINT SET SCREW ROLLER CROWNED YOKE 5/16-18 X 1-1/4 BHSCS 5/16-18 X 1-1/4 FHSC BEARING/BUSHING RAMP LIMIT SWITCH ASM SWITCH MINI SNAP ACTING SWITCH SPACER STD RAMP S/S PPHMS 4-40X1 1/2 #4 sae 5/16od z f/w 12 Qty.
9 Page 47 Item Qty. 1 1 2 1 3 3 4 3 5 3 6 3 7 6 8 2 9 2 10 2 3 Description RAMP STANDARD (RAMP NARROW) RAMP CABLE W/BALL SHANK, CLAMP INSULATED 3/8" 1/4-20 X 1/2 BHSCS 1/4-20 NTE JAM NYLOK 10-32 X 3/4 BHSCS #10 SAE F/W Z 1/4 HI-ALLOY L/W YZ 3/8 USS F/W Z 3/8-16 YZ8 NE NYLOCK 4 2 RAMP SIDE OF HINGE VAN SIDE OF HINGE 10 14 12 5 7 18 6 Part # RLXR4000 (RLXR4000N) RLXR1100 8863T13 1124049 1137020 1124042 1133074 1133891 1133008 1137185 19 8 Item Qty. 11 1 12 12 13 1 14 1 15 4 15 4 15 1 16 0.
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folding raMP MoTor inSTall / reMoval and adJuSTMenT Folding Ramp Motor Install (steps 1-19) Ramp Removal Instructions (steps 1-4 + 15-19) 1. Remove carpeted motor panel. This is held on by two Phillip head screws. 2. Disconnect wires going to limit switches and motor. 3. Unbolt ramp. There are two bolts (3/8) that go into the side of the van above ramp motor and two nuts (3/8) on the floor of the van-one nut is by the motor and one nut is by b-pillar. 4. Remove ramp from van. 5.
folding raMP MoTor inSTall / reMoval and adJuSTMenT Resettable Circuit Breaker 3/8 Nut Pick Up Arm Roller Phillips Head Screws 3/8 Bolt Cable Bolt Adjustment Cam Set Screw Down Adjustment Cams Set Screw Backstop Adjustment Bolt Up Adjustment Cams Limit Switches Page 50 3/8 Nut
rear heaT & air FRONT CONNECTIONS Hose Clamps 705-1012 (6) WELDED ENDS OEM CONNECTORS REAR HEAT & A/C MODEL YEAR 2012-2014 REAR HEAT CONNECTIONS ASSEMBLIES Hose Clamps 705-1012 (6) #B2100-REAR HEAT LINE 5/8” (2 PER) #B01200-RASM - REAR A/C LINE 5/16” #B01201-RASM - REAR A/C LINE ½” #68125530AA - AFTERMARKET O-RING 5/16” #68030834AA - AFTERMARKET O-RING ½” O-RINGS INCLUDED IN A/C ASSEMBLIES REAR BLOWER OEM CONNECTORS WELDED ENDS REAR A/C CONNECTIONS Page 51
reMoTe SYSTeM TrouBleShooTing * If remote does not work first try to operate door and ramp from any interior Rollx Vans user button. If interior Rollx Vans user button operates normally, see below for remote system troubleshooting Symptom Door does not open when One Touch remote is pressed. Neither One Touch remote works. Possible Cause Receiver out of range. Overhead on/off switch is turned to the OFF position. Blown fuse. Remedy Try remote within 10 feet of van. Turn switch to ON position.
reMoTe SYSTeM locaTion & Wiring OTC Remote Receiver (Behind Rear Passenger Quarter Panel Above Rear Heat Unit) OTC Remote Transmitter OTC Remote Receiver (Rear View) BLUE LED Indicator Light ANTENNA To PROGRAMING SWITCH POWER To USER SWITCH CR2016 Batteries (X 2) 1BAMR-ASM ASM #03295-003 FUSE PANEL (BEHIND GLOVE BOX) 1 AMP REMOTE Version 8 1 AMP DOOR DETECTOR 1 AMP CONTROLLER PWR Nuetral Safety To Rollx Vans user switches Ignition Hot BK (8 GA.) 40A FUSE RD (8 GA.
SeaT deTecTor locaTion & deScriPTion Seat Detector Location Seat Detector Description The Rollx Vans Seat Detector essentially simulates the functionality of a driver or passenger front seat in the event where the seats are disconnected from the van (FIG A & B).
Page 55 SEAT DETECTOR V 4.40 POWER SEAT SENSOR YL/GN RD BK GROUND SEAT BELT LG/GY SEAT POS SENSOR LB/WT SEAT POS SENSOR + LB/VT HEADREST + PK/WT HEADREST GND BK/RD SEAT BELT RETRACTOR Ln2 LG/YL SEAT BELT RETRACTOR Ln1 LG/DG SEAT THORAX SQUIB 1 Ln 2 LB/VT SEAT THORAX SQUIB 1 Ln 1 LG/GY #11134-001ASM-DR TO CIGARETE LIGHTER Body Side Wire Body Side 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm RD (20 GA.) GN (20 GA.) BK (20 GA.) - CAV 1 YL/GN (20 GA.
1 BK/RD LG/YL LG/DG LB/VT LG/GY YL/GN RD BK LG/GY LB/WT LB/VT F m ro M OE 15 19 BK (20 GA.) - CAV 17 SEAT SENSOR JUMPER LG/GY (18 GA.) - CAV 21 (LEFT SEAT THORAX SQUIB 1 LINE1) LG/DG (18 GA.) - CAV 19 (DR. SEAT BELT RETRACTOR TENSIONER LINE 1) LB/VT (18 GA.) - CAV 20 (LEFT SEAT THORAX SQUIB 1 LINE 2) 3 TOP 9 20 15 2 4 PINS: A1661-ND QTY 7 A1341-ND QTY 4 # A16037-ND 22 1 SEAT SIDE CONNECTOR 21 8 14 LG/YL (18 GA.) - CAV 18 (DR. SEAT BELT RETRACTOR TENSIONER LINE 2) BK/RD (20 GA.
Page 57 SEAT DETECTOR V 4.40 POWER SEAT SENSOR YL/GN RD BK GROUND SEAT BELT LG/GY SEAT POS SENSOR LB/WT SEAT POS SENSOR + LB/VT HEADREST + PK/WT HEADREST GND BK/RD SEAT BELT RETRACTOR Ln2 LG/YL SEAT BELT RETRACTOR Ln1 LG/DG SEAT THORAX SQUIB 1 Ln 2 LB/VT SEAT THORAX SQUIB 1 Ln 1 LG/GY #11134-001ASM-DR Body Side Wire Body Side 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm RD (12 GA.) RD (20 GA.) (GROUND) (Seat sensor wire for seat detector) 25 A OR/RD (12 GA.) RELOCATED OEM CIRCUIT BREAKER RD (12 GA.
BK/RD LG/YL LG/DG LB/VT LG/GY YL/GN RD BK LG/GY LB/WT LB/VT (GROUND) 19 BK (20 GA.) - CAV 17 SEAT SENSOR JUMPER RD (12 GA.) - CAV 22 (FUSED B+) LG/GY (18 GA.) - CAV 21 (LEFT SEAT THORAX SQUIB 1 LINE1) LG/DG (18 GA.) - CAV 19 (DR. SEAT BELT RETRACTOR TENSIONER LINE 1) LB/VT (18 GA.) - CAV 20 (LEFT SEAT THORAX SQUIB 1 LINE 2) 3 TOP 9 20 15 2 4 PINS: A25033-ND QTY 2 A1661-ND QTY 6 A1341-ND QTY 4 # A16037-ND 22 1 SEAT SIDE CONNECTOR 21 8 14 LG/YL (18 GA.) - CAV 18 (DR.
Page 59 SEAT DETECTOR V 4.40 POWER SEAT SENSOR YL/GN RD BK GROUND SEAT BELT LG/GY SEAT POS SENSOR LB/WT SEAT POS SENSOR + LB/VT HEADREST + PK/WT HEADREST GND BK/RD SEAT BELT RETRACTOR Ln2 LG/YL SEAT BELT RETRACTOR Ln1 LG/DG SEAT THORAX SQUIB 1 Ln 2 LB/VT SEAT THORAX SQUIB 1 Ln 1 LG/GY #11134-001ASM-DR Body Side Wire Body Side 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm RD (20 GA.) RD (12 GA.) BK (12 GA.) - CAV 1 YL/GN (20 GA.) - CAV 17 25 A OR/RD (12 GA.) RELOCATED OEM CIRCUIT BREAKER RD (12 GA.
1 BK/RD LG/YL LG/DG LB/VT LG/GY YL/GN RD BK LG/GY LB/WT LB/VT (GROUND) RD (12 GA.) - CAV 22 (FUSED B+) LG/GY (18 GA.) - CAV 21 (LEFT SEAT THORAX SQUIB 1 LINE1) LG/DG (18 GA.) - CAV 19 (DR. SEAT BELT RETRACTOR TENSIONER LINE 1) LB/VT (18 GA.) - CAV 20 (LEFT SEAT THORAX SQUIB 1 LINE 2) BK (20 GA.) - CAV 17 (SEAT SENSOR JUMPER) LG/YL (18 GA.) - CAV 18 (DR. SEAT BELT RETRACTOR TENSIONER LINE 2) GY/DB (20 GA.) - CAV 15 (HEATED STEERING WHEEL RETURN) LG/VT (20 GA.
Cut off from (BLACK) Memory plug SEAT DETECTOR V 4.40 YL/GN SEAT SENSOR YL/GN POWER RD RD GROUND BK BK SEAT BELT LG/GY SEAT POS SENSOR LB/WT SEAT POS SENSOR +LB/VT PK/WT HEADREST + BK/RD HEADREST GND BK/RD PK/WT SEAT BELT RETRACTOR Ln2 LG/YL SEAT BELT RETRACTOR Ln1 LG/DG SEAT THORAX SQUIB 1 Ln 2 LB/VT SEAT THORAX SQUIB 1 Ln 1 LG/GY #11134-001ASM-DR m 0 2.4 OHM 2.
Page 62 13 11 9 7 5 3 1 4 1 8 6 4 2 14 12 10 1 5 11 19 4 10 18 24 WT/GY (20 GA.) - CAV 4 (CAN BUS +) (SEAT BELT BUCKLE SWITCH) (R.F. HEATED SEAT TEMP SENSE) (SEAT BELT RETRACTOR TENSIONER LINE 2) (HEATED STEERING WHEEL RETURN) (RT. FRONT SEAT HEATER CONTROL) (FUSED OUTPUT) (SEAT POS SENSOR VOLTAGE) (HEATED STEERING WHEEL) (ADJUSTABLE PEDALS MORTOR FORWARD) (SEAT SENSOR JUMPER) BK (12 GA.) - CAV3 BK (12 GA.) - CAV3 RD (12 GA.
Page 63 SEAT DETECTOR V 4.40 SEAT SENSOR YL/GN POWER RD GROUND BK LB/GY SEAT BELT SEAT POS SENSOR WT/LB SEAT POS SENSOR + VT/LB PK/DB HEADREST + BK/RD HEADREST GND SEAT BELT RETRACTOR Ln2 LB/YL SEAT BELT RETRACTOR Ln1 LB/DG SEAT THORAX SQUIB 1 Ln 2 VT/LB SEAT THORAX SQUIB 1 Ln 1 GY/LG #11134-001ASM-PS From Drivers Side seat OR/RD (12 GA.) Body Side Wires To Chassis GND 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm YL/GN (20 GA.
7 1 1 Page 64 4 14 8 BK/RD LG/YL LG/DG GY/LG (18 GA.) - CAV 21 LB/DG (18 GA.) - CAV 19 VT/LB (18 GA.) - CAV 20 LB/YL (18 GA.) - CAV 18 BK (20 GA.) - CAV 17 (Seat sensor wire for seat detector) (SEAT OCCUPANT DETECTION RETURN) (SEAT THORAX SQUIB 1 LINE 1) (SEAT BELT RETRACTOR TENSIONER LINE 1) (SEAT THORAX SQUIB 1 LINE 2) (SEAT BELT RETRACTOR TENSIONER LINE 2) LB/LG (20 GA.) - CAV 9 (SEAT BELT SWITCH SENSE) (SEAT OCCUPANT DETECTION SIGNAL) LB/GY (20 GA.
Page 65 SEAT DETECTOR V 4.40 SEAT SENSOR YL/GN POWER RD GROUND BK LB/GY SEAT BELT SEAT POS SENSOR WT/LB SEAT POS SENSOR + VT/LB PK/DB HEADREST + BK/RD HEADREST GND SEAT BELT RETRACTOR Ln2 LB/YL SEAT BELT RETRACTOR Ln1 LB/DG SEAT THORAX SQUIB 1 Ln 2 VT/LB SEAT THORAX SQUIB 1 Ln 1 GY/LG #11134-001ASM-PS OR/RD (14 GA.) From Drivers Side seat Body Side Wires 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm BK (12 GA.) - CAV 1 YL/GN (20 GA.) - CAV 17 (SEAT OCCUPANT DETECTION SIGNAL) LB/GY (20 GA.
14 8 BK/RD LG/YL LG/DG (GROUND) (SEAT BELT SWITCH SENSE) (SEAT BELT BUCKLE SWICHT SENSE) (HEAD REST GROUND) (PASS SEAT POS SENSOR DATA) (HEAD REST PASS SOLENOID +) (PASS SEAT POS SENSOR VOTAGE) GY/LG (18 GA.) - CAV 21 (SEAT THORAX SQUIB 1 LINE 1) (SEAT BELT RETRACTOR TENSIONER LINE 1) (SEAT THORAX SQUIB 1 LINE 2) LB/DG (18 GA.) - CAV 19 VT/LB (18 GA.) - CAV 20 (FUSED B+) (Seat sensor wire for seat detector) (SEAT BELT RETRACTOR TENSIONER LINE 2) OR/RD (14 GA.
Page 67 SEAT DETECTOR V 4.40 SEAT SENSOR YL/GN POWER RD GROUND BK LB/GY SEAT BELT SEAT POS SENSOR WT/LB SEAT POS SENSOR + VT/LB PK/DB HEADREST + BK/RD HEADREST GND SEAT BELT RETRACTOR Ln2 LB/YL SEAT BELT RETRACTOR Ln1 LB/DG SEAT THORAX SQUIB 1 Ln 2 VT/LB SEAT THORAX SQUIB 1 Ln 1 GY/LG OCCUPANT DETECT SIG LB/DG OCCUPANT DETECT RET LB/LG #11134-001ASM-PS OR/RD (14 GA.) From Drivers Side seat Body Side Wires 1K 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm BK (12 GA.) - CAV 1 YL/GN (20 GA.
14 8 BK/RD LG/YL LG/DG (GROUND) (RIGHT FRONT HEATED SEAT TEMP SENSE) TN/DB (20 GA.) - CAV 12 GY/LG (18 GA.) - CAV 21 (SEAT THORAX SQUIB 1 LINE 1) (SEAT BELT RETRACTOR TENSIONER LINE 1) (SEAT THORAX SQUIB 1 LINE 2) LB/DG (18 GA.) - CAV 19 VT/LB (18 GA.) - CAV 20 (FUSED B+) (Seat sensor wire for seat detector) (SEAT BELT RETRACTOR TENSIONER LINE 2) OR/RD (14 GA.) - CAV 22 (RIGHT FRONT SEAT HEATER CONTROL) LG/VT (20 GA.) - CAV 11 BK (20 GA.
Page 69 SEAT DETECTOR V 4.40 SEAT SENSOR YL/GN POWER RD GROUND BK LB/GY SEAT BELT SEAT POS SENSOR WT/LB SEAT POS SENSOR + VT/LB PK/DB HEADREST + BK/RD HEADREST GND SEAT BELT RETRACTOR Ln2 LB/YL SEAT BELT RETRACTOR Ln1 LB/DG SEAT THORAX SQUIB 1 Ln 2 VT/LB SEAT THORAX SQUIB 1 Ln 1 GY/LG OCCUPANT DETECT SIG LB/DG OCCUPANT DETECT RET LB/TN #11134-001ASM-PS OR/RD (14 GA.) From Drivers Side seat Body Side Wires To Chassis GND 1K 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm RD (20 GA) YL/GN (20 GA.
8 7 1 14 Page 70 BK/RD LG/YL LG/DG GY/LG (18 GA.) - CAV 21 LB/DG (18 GA.) - CAV 19 VT/LB (18 GA.) - CAV 20 LB/YL (18 GA.) - CAV 18 BK (20 GA.
Page 71 SEAT DETECTOR V 4.40 SEAT SENSOR YL/GN POWER RD GROUND BK LB/GY SEAT BELT SEAT POS SENSOR WT/LB SEAT POS SENSOR + VT/LB PK/DB HEADREST + BK/RD HEADREST GND SEAT BELT RETRACTOR Ln2 LB/YL SEAT BELT RETRACTOR Ln1 LB/DG SEAT THORAX SQUIB 1 Ln 2 VT/LB SEAT THORAX SQUIB 1 Ln 1 GY/LG OCCUPANT DETECT SIG LB/DG OCCUPANT DETECT RET LB/TN #11134-001ASM-PS OR/RD (14 GA.) From Drivers Side seat Body Side Wires To Chassis GND 1K 2.4 OHM 2.4 OHM 1K 510 ohm 510 ohm RD (20 GA) YL/GN (20 GA.
8 7 1 14 Page 72 BK/RD LG/YL LG/DG (RIGHT FRONT SEAT HEATER CONTROL) (RIGHT FRONT HEATED SEAT TEMP SENSE) TN/WT (20 GA.) - CAV 10 LG/VT (20 GA.) - CAV 11 TN/DB (20 GA.) - CAV 12 LB/YL (18 GA.) - CAV 18 GY/LG (18 GA.) - CAV 21 (FUSED B+) (SEAT THORAX SQUIB 1 LINE 1) (SEAT BELT RETRACTOR TENSIONER LINE 1) (SEAT THORAX SQUIB 1 LINE 2) (SEAT BELT RETRACTOR TENSIONER LINE 2) OR/RD (14 GA.
oTc Wiring (WiTh The door oPen liMiT SWiTch) ROLLX VANS ONE TOUCH CONT ITF Harness V6/ OTC Board V8 MOD TIPM KNEEL DISABLE (ON / OFF) SWITCH (ASM #03220-001) VT N/C VT (20 GA.) 1 N/C DB / YL (20 GA.) AUX I/O 4 (Fuse box under hood) BK DB / YL (20 GA.) BK (20 GA. BK (20 GA.) CUT Twisted pairs run down B-Pillar 1 BACK SIDE WT/OR WT/GY WT/OR (CAV 5) (Chrysler Door Ajar Circuit) N/C BK (10 GA.) (User switch) (Neutral Safety) (Door Open Limit) (Door Closed Limit) DB (20 GA.
oTc Wiring (WiTh The door oPen liMiT SWiTch) NTROLLER WIRING DIAGRAM BuilT Before 8/26/2013 OD E-F (W/ Limit Switch) Compustar Remote ROLLX VANS USER / RESET SWITCHES (ASM #03220-005) D-PILLAR DASH RESET SWITCH (8/21/06) 12/27/12 DASH C-PILLAR ITF RAMP OVERRIDE SWITCH (DRIVER SIDE B PILLAR) #05175-001 BK DB BK DB BK DB OUT BK DB DB (20 GA.) .) 0 GA. X 3) DB (20 GA.) BK (20 GA.) BK (20 GA.) IN BK (20 GA.) WT / RD (20 GA.) X 3 * BK (20 GA. X 3) C309 7 OR (20 GA.
oTc Wiring (WiTh The door deTecTor) ROLLX VANS ONE TOUCH C ITF Harness V6/ OTC Board V8 MOD * = For pictures of location see Important Information and Location Section in Service Manual *UNIVERSAL DOOR DETECTOR (13104-001ASM) Italic Font = OEM Wire LOCATION: Passengers D-PILLAR 12 BACK SIDE N/C (Door Closed Status In) VT (20 GA.) (QUAD B + IN) BL (20 GA.) (QUAD A + IN) PK (20 GA.) (GND) N/C 1 4 1 OR/RD (20 GA.) (Door Open Status out) BL/YL (20 GA.) (Reset) BK (20 GA.
oTc Wiring (WiTh The door deTecTor) 9/23/2013 H CONTROLLER WIRING DIAGRAM MOD F (W/ Door Detector) DASH RESET SWITCH (8/21/06) 4 DB BK BuilT afTer 8/26/2013 ROLLX VANS USER / RESET SWITCHES (ASM #03220-005) D-PILLAR DB DASH C-PILLAR BK BK DB BK DB 1 DB (20 GA.) BK (20 GA.) BK (20 GA. X 3) LOCATION: Back side of the lower slider door track R odule Right BK (20 GA. X 3) DB / YL (20 GA.) DMRR Door Module Right Rear ITF RAMP OVERRIDE SWITCH (DRIVER SIDE B PILLAR) #05175-001 BK (20 GA.
oTc Wiring (WiTh The door deTecTor no can BuS) ROLLX VANS ONE TOUCH CONT ITF Harness V6/ OTC Board V8 MOD * = For pictures of location see Important Information and Location Section in Service Manual 12 N/C BACK SIDE *UNIVERSAL DOOR DETECTOR (13104-001ASM) Italic Font = OEM Wire LOCATION: Passengers D-PILLAR (Door Closed Status In) VT (20 GA.) (QUAD B + IN) N/C 1 4 BL (20 GA.) (QUAD A + IN) PK (20 GA.) (GND) 1 OR/RD (20 GA.) (Door Open Status out) BL/YL (20 GA.) (Reset) BK (20 GA.
oTc Wiring (WiTh The door deTecTor no can BuS) 3/13/2014 NTROLLER WIRING DIAGRAM OD F (Dropped the CAN BUS) DASH RESET SWITCH (8/21/06) 4 DB BK BuilT afTer 3/17/2014 ROLLX VANS USER / RESET SWITCHES (ASM #03220-005) D-PILLAR DB DASH C-PILLAR BK BK DB BK DB 1 DB (20 GA.) BK (20 GA.) BK (20 GA. X 3) LOCATION: Back side of the lower slider door track R odule Right BK (20 GA. X 3) DB / YL (20 GA.
oTc Wiring (WiTh Wing WindoW inTerface) ROLLX VANS ONE TOUCH CON ITF Harness V7/ OTC Board V8 MO * = For pictures of location see Important Information and Location Section in Service Manual Italic Font = OEM Wire PSDMR Power Sliding Door Module Right LOCATION: Back side of the lower slider door track VT N/C BK (20 GA.) VT/BL (20 GA.) VT/YL (20 GA.) N/C VT (20 GA.) N/C BL/YL (20 GA.) 1 4 1 12 N/C BACK SIDE *UNIVERSAL DOOR DETECTOR (13104-001ASM) VT (20GA.
OTC WIRING (With Wing Window Interface) 3/24/2014 ONTROLLER WIRING DIAGRAM MOD H (W/ Wing Window Interface) Right Rear Wing Window Motor ROLLX VANS USER / RESET SWITCHES (ASM #03220-005) D-PILLAR BK DB BK VT/BL VT/YL e Door snake r) OR / BL Rear Window Signal BL /YL OR / YL Rear Window Return OR / YL ITF RAMP OVERRIDE SWITCH #05175-001 OUT LOCATION: Driver’s Side B-Pillar RD (20 GA.) BL /YL * RD (20GA.) FUSE PANEL (BEHIND GLOVE BOX) BK (20 GA.
rollX vanS PoWer door (MoTor Bar) Wiring Rollx Vans Power Door (Mo Touchtronic Power Touch 1550 2 1 3 DOOR LOCK LIMIT SWITCH #6X284 IN PASSENGER DOOR (WHEN CLOSED, SENDS POWER TO HARDWIRED SWITCHES) NC NO COM VT (14) RAMP UP LIMIT SWITCH #03220-004 RMP DWN NC NO COM RAMP POWER SWITCH ON DB (14 GA.) WT (14 GA.) CLOSE RD (14) - RD (10 GA.) YL (14 GA.) DG (14 GA.) BK (14) + BR (14 GA.) WT (14) RD (10) FUSE 30 A OFF FUSE 15 A KNEEL TN (16 GA.
rollX vanS PoWer door (MoTor Bar) Wiring 7/9/2013 Motor Bar) Wiring Diagram v2 50-R Remote System (Jan. 2011) YL (16 GA.) TO OEM DOOR AJAR NC VT (14) NO MOTOR BAR C PILLAR USER SWITCH #310-1059 YL DB COM KNEELER BK (14 GA.) 85 DOOR CLOSE BR PK (14 GA.) 87A 87 85 RAMP DOWN 30 86 87A 87 85 RAMP UP 30 86 87A 87 85 KNEEL DOWN 87 85 WT (16 GA.) KNEEL UP RELAYS (#5-1393302-8) LOCATED IN OEM SPARE TIRE KIT COMPARTMENT Page 82 YL (14 GA.) YL (14 GA.) 86 BR (14 GA.
MainTenance inforMaTion Doors Door track - Periodically make sure lower door track is free of debris and vacuum track out. Make certain to clear out any water and ice that may be present. In the front of each door track there are plugs that can be removed to allow an air hose to be inserted to help remove debri. Rollx Vans power door (If equipped) - Every 6 months lube the gear rack (bar) with a high quality white lithium grease. Make sure to clean off any old grease first.
WarranTY New Rollx Vans Van Warranty Coverage Information Rollx Vans provids a limited warranty on its minivan against defects in material or workmanship for a period of 3 years or 36,000 miles, whichever comes first. For warranty specifics please refer to an Owner’s Manual or contact Rollx Vans Customer Service. For all warranty or reimbursement needs, you must have prior authorization by the Rollx Vans Service Department. 1.
