2001 CHRYSLER VOYAGER service

INSPECTION
Hold the cap in your hand,top side up(Fig. 21).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.
Hold the cleaned cap in your hand,upside down.
If any light can be seen between vent valve and the
rubber gasket, replace the cap.Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
RADIATOR FAN
DESCRIPTION
The dual radiator fans are mounted to the back
side of the radiator (Fig. 22). The radiator fan consist
of the fan blade, electric motor and a support shroud
which are all serviced as an assembly.
OPERATION
RADIATOR FAN OPERATION CHART
COOLANT TEMPERATURE A/C PRESSURE
Fan Operation
Speeds:Initial Max Initial Max
Fan On: 104ÉC (220ÉF) 110ÉC (230ÉF) Fan
Speed Duty-Cycles
(Ramps-up) from
30% to 99%1,724 Kpa (250 psi) 2,068 Kpa (300 psi)
Fan Speed
Duty-Cycles
(Ramps-up) from
30% to 99%
Fan Off: 101ÉC (214ÉF) Fan Speed
Duty-Cycles
(Ramps-down) from
99% to 30%1,710 Kpa (248 psi) Fan Speed
Duty-Cycles
(Ramps-down) from
99% to 30%
DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR
RADIATOR FAN DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
2. Fan blade striking a surrounding
object.2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or A/C
condenser.3. Remove obstructions and/or
clean debris.
4. Electric fan motor defective. 4. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
ELECTRIC FAN MOTOR DOES
NOT OPERATE1. Fan relay, powertrain control
module (PCM), coolant temperature
sensor, or wiring defective.1. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
2. Defective A/C pressure
transducer.2. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
7a - 26 ENGINERG
RADIATOR PRESSURE CAP (Continued)

AUDIO
TABLE OF CONTENTS
page page
AUDIO
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................1
ANTENNA BODY & CABLE
DESCRIPTION............................3
OPERATION.............................3
DIAGNOSIS AND TESTING..................3
REMOVAL...............................4
INSTALLATION............................4
CD CHANGER
DESCRIPTION............................6
OPERATION.............................6
REMOVAL...............................6
INSTALLATION............................6
CHOKE
DIAGNOSIS AND TESTING..................6
D-PILLAR SPEAKER
REMOVAL...............................6
INSTALLATION............................7
DASH PANEL SPEAKER
REMOVAL...............................7INSTALLATION............................7
DOOR MOUNTED SPEAKER
REMOVAL...............................7
INSTALLATION............................7
QUARTER PANEL SPEAKER
REMOVAL...............................8
INSTALLATION............................8
RADIO
DIAGNOSIS AND TESTING..................8
REMOVAL...............................9
INSTALLATION............................9
RADIO NOISE SUPPRESSION COMPONENTS
DESCRIPTION............................9
OPERATION.............................9
REMOTE SWITCHES
DESCRIPTION...........................10
OPERATION.............................10
DIAGNOSIS AND TESTING.................11
REMOVAL..............................11
INSTALLATION...........................12
AUDIO
DESCRIPTION
There are four different system combinations avail-
able on the RS models. The available radio options
are:
²AM/FM Cassette
²AM/FM Compact Disc with Compact Disc
Changer
²AM/FM Cassette with single Compact Disc
Player
²AM/FM Cassette with Compact Disc Changer
All factory installed radio receivers are stereo Elec-
tronically Tuned Radios (ETR) and include and elec-
tronic digital clock function.
OPERATION
Operating instructions for the factory installed
audio systems can be found in the Owner's Manual
provided with this vehicle.
DIAGNOSIS AND TESTING
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RSAUDIO8A-1

CONDITION POSSIBLE CAUSE CORRECTION
4. POOR ANTENNA
CONNECTION AT
RADIO OR IN LINE.4. SEAT CONNECTOR.
NO/POOR TAPE
OPERATION.1. FAULTY TAPE. 1. INSERT KNOWN GOOD TAPE AND TEST OPERATION.
2. FOREIGN OBJECTS
BEHIND TAPE DOOR.2. REMOVE FOREIGN OBJECTS AND TEST OPERATION.
3. DIRTY CASSETTE
TAPE HEAD.3. CLEAN HEAD WITH MOPAR CASSETTE HEAD CLEANER.
4. FAULTY TAPE DECK. 4. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO COMPACT
DISC
OPERATION1. FAULTY CD. 1. INSERT KNOWN GOOD CD AND TEST OPERATION.
2. FOREIGN MATERIAL
ON CD.2. CLEAN CD AND TEST OPERATION.
3. CONDENSATION ON
CD OR OPTICS.3. ALLOW TEMPERATURE OF VEHICLE INTERIOR TO
STABILIZE AND TEST OPERATION.
4. FAULTY CD PLAYER. 4. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
ANTENNA BODY & CABLE
DESCRIPTION
All models use a fixed-length stainless steel rod-
type antenna mast, installed at the right front fender
of the vehicle. The antenna mast is connected to the
center wire of the coaxial antenna cable, and is not
grounded to any part of the vehicle.
OPERATION
To minimize static, the antenna base must have a
good ground. The coaxial antenna cable shield (the
outer wire mesh of the cable) is grounded to the
antenna base and the radio chassis.
The antenna coaxial cable has an additional dis-
connect, located near the right end of the instrument
panel. This additional disconnect allows the instru-
ment panel assembly to be removed and installed
without removing the radio.
The factory-installed Electronically Tuned Radios
(ETRs) automatically compensate for radio antenna
trim. Therefore, no antenna trimmer adjustment is
required or possible when replacing the receiver or
the antenna.
DIAGNOSIS AND TESTING
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-ING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
The ohmmeter test lead connections for each test
are shown in (Fig. 1).
Fig. 1 Antenna Test Points
RSAUDIO8A-3
AUDIO (Continued)

(4) Connect battery negative cable.
QUARTER PANEL SPEAKER
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove speaker grill by prying away from trim
panel.
(3) Remove speaker retaining screws (Fig. 9).
(4) Disconnect wire harness connector from
speaker.
INSTALLATION
(1) Connect the wire harness to the speaker.
(2) Install the speaker retaining screws.
(3) Install speaker grill by pressing into the trim
panel.
(4) Connect the battery negative cable.
RADIO
DIAGNOSIS AND TESTING
If the vehicle is equipped with remote radio
switches located on the backs of the steering wheel
spokes, and the problem being diagnosed is related to
one of the symptoms listed below, be certain to check
the remote radio switches and circuits as described
in this group, prior to attempting radio diagnosis or
repair.
²Stations changing with no remote radio switch
input
²Radio memory presets not working properly
²Volume changes with no remote radio switch
input
²Remote radio switch buttons taking on other
functions
²CD player skipping tracks
²Remote radio switch inoperative.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION:
The speaker output of the radio is a ªfloating
groundº system. Do not allow any speaker lead to
short to ground, as damage to the radio may result.
(1) Check the fuse(s) in the junction block and the
Intelligent Power Module. If OK, go to Step 2. If not
OK, repair the shorted circuit or component as
required and replace the faulty fuse(s).
(2) Check for battery voltage at the fuse in the
Intelligent Power Module. If OK, go to Step 3. If not
Fig. 8 DOOR SPEAKER
1 - DOOR SPEAKER
2 - HARNESS CONNECTOR
Fig. 9 QUARTER PANEL SPEAKER
1 - SPEAKER
2 - TRIM PANEL
8A - 8 AUDIORS
DOOR MOUNTED SPEAKER (Continued)

DIAGNOSIS AND TESTING
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
itor to discharge before further service.
(2) Remove the remote radio switch(es) from the
steering wheel. (Refer to 8 - ELECTRICAL/AUDIO/
REMOTE SWITCHES - REMOVAL).
(3) Use an ohmmeter to check the switch resis-
tance as shown in the Remote Radio Switch Test
table (Fig. 16).
REMOTE RADIO SWITCH TEST
SWITCH POSITION RESISTANCE
VOLUME UP 7320 OHMS
VOLUME DOWN 1210 OHMS
SEEK UP 4530 OHMS
SEEK DOWN 2050 OHMS
PRE-SET STATION ADVANCE 10 OHMSNOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
(4) If the switch resistance checks OK, go to Step
5. If not OK, replace the faulty switch.
(5) Check for continuity between the ground cir-
cuit cavity of the switch wire harness connector and
a good ground. There should be continuity. If OK, go
to Step 6. If not OK, repair the open circuit as
required.
(6) Unplug the 24-way white wire harness connec-
tor from the Body Control Module (BCM). Check for
continuity between the radio control circuit cavity of
the remote radio switch wire harness connector and a
good ground. There should be no continuity. If OK, go
to Step 7. If not OK, repair the short circuit as
required.
(7) Check for continuity between the radio control
circuit cavities of the remote radio switch wire har-
ness connector and the BCM wire harness connector.
There should be continuity. If OK, refer to the proper
Diagnostic Procedures manual to test the BCM and
the CCD data bus. If not OK, repair the open circuit
as required.
REMOVAL
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
itor to discharge before further service.
(2) Remove the driver side airbag module from the
vehicle. Refer to ELECTRICAL/RESTRAINTS/
DRIVER AIR BAG.
(3) Remove the steering wheel from the steering
column. Refer to STEERING/COLUMN/STEERING
WHEEL.
(4) Unplug the wire harness connector from the
remote radio switch (s).
(5) Remove three screws securing steering wheel
rear cover.
(6) Remove the remote radio switch from the steer-
ing wheel by depressing tabs on each side of each
switch.
Fig. 16 Remote Radio Switches
1 - WHITE REAR SWITCH
2 - BLACK REAR SWITCH
RSAUDIO8A-11
REMOTE SWITCHES (Continued)

NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
INSTALLATION
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.(1) Install remote radio switch to the steering
wheel.
(2) Install three screws securing steering wheel
rear cover.
(3) Connect the wire harness to the remote radio
switch.
(4) Install the steering wheel. Refer to STEERING/
COLUMN/STEERING WHEEL.
(5) Install the driver side airbag module. Refer to
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG.
(6) Connect the battery negative cable.
8A - 12 AUDIORS
REMOTE SWITCHES (Continued)

CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME/BUZZER
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................1
CHIME SYSTEM.........................1
DOME LAMP ON CHIME..................2
ENGINE TEMPERATURE CRITICAL CHIME....2EXTERIOR LAMPS ON CHIME..............2
KEY-IN IGNITION CHIME..................2
LOW OIL PRESSURE CHIME...............2
SEAT BELT CHIME.......................3
SEAT BELT LAMP.......................3
TURN SIGNAL ON CHIME.................3
WARNING LAMP ANNOUNCEMENT CHIME....3
CHIME/BUZZER
DESCRIPTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
The chime/buzzer system provides the driver with
warning chimes for:
²Seat Belt
²Exterior Lamps ON
²Key-In Ignition
²Engine Temperature Critical
²Turn Signals ON
²Dome Lamp ON
²Low Oil Pressure
²High Speed Warning
²Warning Lamp Announcement
²Key-In Accessory
OPERATION
The Chime/Buzzer Warning System is diagnosed
using a DRBIIItscan tool. Refer to the proper Body
Diagnostic Procedures Manual.
DIAGNOSIS AND TESTING - CHIME SYSTEM
NO TONE WHEN IGNITION SWITCH IS TURNED ON
AND DRIVER'S SEAT BELT IS NOT BUCKLED.
(1) Using a DRBIIItscan tool, actuate chime
(BCM actuates).
(2) Using a voltmeter, check for voltage:
(a) BCM has two battery feeds at pin 1 and pin
5 of the 6±way connector.
(b) Pin 5 of the (BX2) 32 way connector of the
BCM for ignition feed.
(c) Check voltage (PX2) connector, pin 34 for 12v.
(d) If voltage OK, go to step Step 3
(e) If NO voltage repair as necessary. Refer to
the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pin-
out and location views for the various wire harness
connectors, splices and grounds.
(3) Check driver's seat belt buckle switch input
(form ORC) for a closed circuit when not buckled. If
input not seen, look for open in wiring or switch. The
switch is grounded when belt is not buckled.
(4) Verify PCI data bus communication between
ORC and BCM.
NO FASTEN SEAT BELT LAMP WHEN IGNITION
SWITCH IS TURNED ON.
(1) Check for burned out lamp.
(2) Using a voltmeter check for voltage at the clus-
ter conncctor:
(a) Pin 2 of the mechanical instrument cluster
for battery feed.
(b) Pin 11 of the mechanical instrument cluster
for ignition voltage.
(3) Repair as necessary.
RSCHIME/BUZZER8B-1

(2) Reconnect the 24±way electrical and the pump/
motor connector. (Fig. 2)
(3) Install the battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(4) Install the screw securing the coolant filler
neck to the battery tray.
(5) Reconnect the vacuum hose to the coolant tank
built into the battery tray.
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(7) Reconnect the battery cables.
(8) Connect a DRBIIItto the vehicle and initialize
the system.
DATA LINK CONNECTOR
DESCRIPTION
The data link connector is located inside the vehi-
cle, below instrument panel next to the center col-
umn (Fig. 4) .
OPERATION
The data link connector (diagnostic connector)
links the DRB scan tool with the Powertrain Control
Module (PCM). Refer to On-Board Diagnostics in the
General Diagnosis section of this group.
FRONT CONTROL MODULE
DESCRIPTION
The Front Control Module (FCM) is a micro con-
troller based module located in the engine compart-
ment (Fig. 5). This FCM mates to the power
distribution center to form the Intelligent PowerModule (IPM). The intelligent power module connects
directly to the battery and provides the primary
means of circuit protection and power distribution for
all vehicle electrical systems. The front control mod-
ule controls power to some of these vehicle systems
electrical and electromechanical loads based on
inputs received from hard wired switch inputs and
data received on the PCI bus circuit (J1850).
For information on theIntelligent Power Mod-
ule(IPM)Refer to the Power Distribution Sec-
tionof the service manual.
OPERATION
As messages are sent over the PCI bus circuit, the
front control module reads these messages and con-
trols power to some of the vehicles electrical systems
by completing the circuit to ground (low side driver)
or completing the circuit to 12 volt power (high side
driver). The following functions arecontrolledby
the Front Control Module:
²Occupant Restraint Controller Voltage
²Headlamp Power with Voltage Regulation
²Side Airbag Voltage
²Electronic Transaxle (Gasoline engine Vehicles)
²Brake Transmission Shift Interlock Functions
(BTSI)
²Front Windshield Wiper ªONº Relay Actuation
²Front Windshield Wiper ªHIº & ªLOº Relay
Actuation
²Front Washer Motor
²Rear Washer Motor
Fig. 4 DATA LINK CONNECTOR
Fig. 5 FRONT CONTROL MODULE
1 - FRONT CONTROL MODULE
RSELECTRONIC CONTROL MODULES8E-5
CONTROLLER ANTILOCK BRAKE (Continued)