2001 CHRYSLER VOYAGER service

POWER LIFTGATE SYSTEM INHIBITORS
²The Power Liftgate may not operate in extreme
temperatures. These extreme temperatures will be
approximately -12É F (-24.4É C) on the low side and
143É F (61.6É C) for the high side. A chime/thermister
assembly in the rear light bar assembly monitors the
outside temperature.
²The vehicles transmission must be in park or
neutral for the power liftgate to start a cycle.
²If multiple obstacles are detected during the
same power open or close cycle the liftgate goes into
manual operation.
²If severe Diagnostic Trouble Codes (DTC) are
stored in the power liftgate control module.
POWER LIFTGATE SYSTEM CAUTIONS AND
WARNINGS
WARNING: ALWAYS DISCONNECT THE NEGATIVE
BATTERY CABLE BEFORE ATTEMPTING ANY
POWER LIFTGATE SYSTEM SERVICE.
WARNING: THERE IS A SMALL AREA ON BOTH
SIDES OF THE LOWER POWER LIFTGATE WHICH
ARE NOT PROTECTED BY PINCH SENSORS.
EXTREME CARE MUST BE TAKEN TO PREVENT
OBJECTS FROM ENTERING THIS AREA ONCE THE
LIFTGATE REACHES THE SECONDARY LATCH
CONTACT (APPROXIMATELY 1/2 INCH BEFORE
FULLY CLOSED).
WARNING: NEVER ATTEMPT TO ENTER OR EXIT
THE VEHICLE WITH THE LIFTGATE IN MOTION.
YOU COULD DAMAGE THE POWER LIFTGATE SYS-
TEM AND/OR COMPONENTS AND/OR CAUSE PER-
SONAL INJURY.
WARNING: NEVER STICK OBJECTS IN THE POWER
LIFTGATE WHEN CINCHING CLOSED. YOU COULDDAMAGE THE VEHICLE, POWER LIFTGATE SYS-
TEM COMPONENTS AND/OR CAUSE PERSONAL
INJURY.
DIAGNOSIS AND TESTING - POWER LIFTGATE
SYSTEM
The power opening and closing power liftgate sys-
tem is a complex system containing many compo-
nents and modules. In order to obtain conclusive
testing the Programmable Communications Interface
(J1850) data bus network and all of the electronic
modules that provide inputs to, or receive outputs
from the power liftgate system must be checked.
The power liftgate system was designed to be diag-
nosed with an appropriate diagnostic scan tool, such
as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the power liftgate system
requires the use of a DRB IIItscan tool and the
proper Body Diagnostic Procedures manual. The
DRB IIItcan be used to observe various switch sta-
tuses throughout the power liftgate system to help
the technician diagnose a defective switch or compo-
nent. The DRB IIItcan also be used to actuate var-
ious components throughout the power liftgate
system to help the technician diagnose a defective
component.
Before any testing of the power liftgate system is
attempted, the battery should be fully charged, all
built-in power liftgate system inhibitors read and
understood (Refer to power liftgate system operation)
and all wire harness and ground connections
inspected around the affected areas on the vehicle.
Following are quick reference diagnostic tables to
help when diagnosing and testing the power liftgate
system.
8N - 4 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

STANDARD PROCEDURE - LIFTGATE
ADJUSTMENT
In order for the power liftgate system to function
properly the liftgate must move freely and smoothly.
The power liftgate system can acommodate for some
minor changes in the effort required to move the lift-
gate. However, in extreme conditions the liftgate may
need to be mechanicaly adjusted for proper fit and
finish. Refer to the Liftgate Adjustment procedure in
the Body section of the service manual for detailed
instructions.
If a problem exists with the power liftgate and it is
suspected to be extreme effort check the liftgate prop
rods and hinges for free movement. Use a known
good vehicle for liftgate effort comparison.
NOTE: Routine application of Mopar MP-50Tor
equivalent on the chrome prop rod shafts and lift-
gate latch and hinges will help keep the liftgate in
good working order.
STANDARD PROCEDURE - POWER LIFTGATE
LEARN CYCLE
Any time a power liftgate component is removed,
replaced or a liftgate adjustment is performed a learn
cycle must be performed. This learn cycle enables the
power liftgate control module to learn or relearn
information (travel limits, resistance to door travel,
etc.) which allows it to perform properly and safely.
To perform a learn cycle do the following:
(1) Obtain a DRB IIItscan tool.
(2) Connect the DRB IIItto the vehicle and check
for any power liftgate system stored trouble codes,
correct and erase any stored codes.
(3) Using the DRB IIIt, Go into Test Routine
Menu and select the power open command.
(4) Select the power close command.
(5) The liftgate learn cycle is complete.
If a DRB IIItscan tool is not available the learn
cycle can be performed by actuating the liftgate by
using any of the normal command switches. Be cer-
tain to cycle the liftgate through a complete open and
close cycle before returning the vehicle to service.
NOTE: If the power liftgate will not complete a full
cycle a problem exists with the power liftgate sys-
tem. (Refer to 8 - ELECTRICAL/POWER DOORS -
DIAGNOSIS AND TESTING) .
PINCH SENSOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize two
pinch sensors, one is located on each side of the lift-
gate (Fig. 4). These sensors look like weather-strips,
however they consist of pieces of electrically conduc-
tive rubber (tapeswitch), wires, resistor, double sided
tape, and a plastic carrier. They are used to indicate
an obstruction during a power close cycle.
OPERATION
During a power liftgate close cycle, if either of the
two conductive rubber strips (tapeswitch) of the
pinch sensor come in contact with an obstacle, the
pinch sensor circuit is completed. This tells the
power liftgate control module that a obstruction is
felt. The control module will stop the liftgate imme-
diately and return it to the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove trim panel from liftgate. Refer to Body
for the procedure.
Fig. 4 PINCH SENSOR LOCATION
1 - LIFTGATE
2 - PINCH SENSOR ASSEMBLY
3 - POWER LIFTGATE LINK ROD
4 - PINCH SENSOR WIRE HARNESS CONNECTOR
5 - PINCH SENSOR WIRE HARNESS
RSPOWER LIFTGATE SYSTEM8N-9
POWER LIFTGATE SYSTEM (Continued)

(3) Disconnect the pinch sensor wire harness con-
nector (Fig. 4).
(4) Remove screws holding the pinch sensor to lift-
gate.
(5) Feed the pinch sensor wire harness out of the
liftgate and remove the sensor from the vehicle.
INSTALLATION
(1) Position the pinch sensor and install screws
holding the sensor to the liftgate. Torque screws to
25 in. lbs.
(2) Install wire harness grommet in liftgate flange
and route, connect the pinch sensor wire harness
connector.
(3) Install the trim panel on the liftgate. Refer to
the Body section for the procedure.
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the pinch sensor.
(6) Verify power liftgate system and pinch sensor
operation. Cycle the power liftgate through one com-
plete open and close cycle, during the final close cycle
press the pinch sensor to verify the power liftgate
detects an obstruction and returns to the full open
position.
WARNING: USE EXTREME CAUTION WHEN TEST-
ING PINCH SENSOR OPERATION.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
full open switch. This switch is located on the gear
motor housing (Fig. 5) and is used to signal the
power liftgate module when the liftgate is in the full
open position. Two wires are used from the full open
switch contacts to the gear motor assemblies main
electrical connector.
The full open switch is a serviceable component.
Consult your Mopar parts catalog for a specific part
number.
OPERATION
When the power liftgate reaches the full open posi-
tion, the gear motor housing mounted full open
switch electrical contacts come in contact with each
other. This sends a ground signal to the power lift-
gate control module, telling the module that the lift-
gate has reached the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).
(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor (Fig. 5). Refer to the Wiring section of the service
manual for detailed instructions.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
Fig. 5 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
8N - 10 POWER LIFTGATE SYSTEMRS
PINCH SENSOR (Continued)

(6) Verify power liftgate system and full open
switch operation. Cycle the power liftgate through
one complete open and close cycle, this will allow the
power liftgate control module to relearn its cycle with
the new components.
LIFTGATE MOTOR
DESCRIPTION
Vehicles equipped with a power liftgate, utilize a
liftgate gear motor assembly (Fig. 6). The gear motor
assembly consists of a DC motor, hall effect sensor,
engage actuator, full open switch, lift gear, aluminum
housing, drive gears and wire harness. The gears and
motor portion of the assembly provides the power
and torque required to open or close the liftgate
under the worst case conditions. The hall effect sen-
sor is used to provide the liftgate control module with
a speed reading, which is used to monitor the resis-
tance of liftgate travel. This speed reading also
allows the power liftgate control module to detect
obstructions and move the liftgate accordingly. The
engage actuator is used to toggle between power
open/close mode and full manual mode when desired.
The full open switch is used to let the power liftgate
control module know when the liftgate is approach-
ing the full open position.Serviceable components of the power liftgate gear
motor assembly are the complete gear motor assem-
bly, motor and wire harness, lift gear and control rod,
engage actuator, full open switch and the transverse
bracket. Refer to additional information in this group
for more component details.
OPERATION
With the push of a power liftgate command switch
(liftgate closed), the power liftgate control module
will signal the latch assembly to release the door
from its primary closed and latched position to the
released and movable position. The liftgate motor
mounted, engage actuator then engages the liftgate
motor assembly, which moves the liftgate into the
open position. The liftgate motor provides the torque
and power to move the door to its full open or closed
position(Refer to 8 - ELECTRICAL/POWER DOORS -
OPERATION) for additional information.
REMOVAL
The power liftgate motor can be serviced in two
different ways. The first of which is called out here,
the complete gear motor assembly. The second way
includes the motor, aluminum housing, drive gears
and wire harness assembly. To perform this service
procedure, use the following procedure to remove the
gear motor assembly from the vehicle. Then refer to
the other procedures called out this section to trans-
fer the remaining components (engage actuator, full
open switch, transverse bracket and lift gear and
rod) to the replacement motor assembly.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left rear D-pillar trim panel from
the vehicle. Refer to the Body section for the proce-
dure.
(3) Disconnect the wire harness connector from the
motor assembly (Fig. 6).
(4) Remove the two bolts from the motor housing
and the one bolt from the transverse mount bracket.
(5) Grab the liftgate motor assembly and lift
upward and out to unhook the motor assembly from
the D-pillar.
(6) Remove the liftgate motor assembly from the
vehicle.
INSTALLATION
(1) Using the motor housing tab, hook the liftgate
motor assembly on the D-pillar.
(2) Install the three motor assembly retaining
bolts. Torque the two rear most bolts first to 9.5 N´m
(85 in. lbs.). Torque the remaining bolt next to the
window actuator to 9.5 N´m (85 in. lbs.).
(3) Connect the liftgate motor assembly electrical
connector.
Fig. 6 POWER LIFTGATE COMPONENTS
1 - POWER LIFTGATE GEAR MOTOR ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
RSPOWER LIFTGATE SYSTEM8N-11
FULL OPEN SWITCH (Continued)

(4) Install the D-pillar trim panel on the vehicle.
Refer to Body for the procedure.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(7) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
ENGAGE ACTUATOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
power liftgate engage actuator (Fig. 7). The 12 volt
engage actuator provides the engagement and disen-
gagement of the liftgate gear motor to the lift gear by
way of an over center link, activated by a lever.
The engage actuator is a serviceable component
and cannot be repaired, if found to be faulty it must
be replaced.
OPERATION
The engage actuators normal position is disen-
gaged. When a power liftgate open or close command
is generated from any of the command switches, thepower liftgate control module signals the engage
actuator to move its lever to the engaged position.
This engages the gear motor to the lift gear, so when
the motor turns the lift gate moves upward or down-
wards depending on its current position.
During a manual liftgate open or close cycle the
engage actuator is disengaged, allowing unrestricted
liftgate movement.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left rear D-pillar trim from the
vehicle. Refer to Body for the procedure.
(3) Using your hand manually engage the actuator
link rod, this must be done to access one of the
engage actuator retaining screws.
(4) Remove the two engage actuator retaining
screws (Fig. 8).
(5) Disconnect the engage actuator electrical con-
nector and remove the engage actuator from the
vehicle.
INSTALLATION
(1) Position the engage actuator and connect the
engage actuator electrical connector.
(2) Install the two engage actuator retaining
screws.
(3) Manually disengage the actuator.
Fig. 7 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 8 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
8N - 12 POWER LIFTGATE SYSTEMRS
LIFTGATE MOTOR (Continued)

(4) Install the left rear D-pillar trim on the vehi-
cle. Refer to Body for the procedure.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and engage actua-
tor operation. Cycle the power liftgate through one
complete open and close cycle.
TRANSVERSE BRACKET
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
transverse bracket (Fig. 9). This bracket is not differ-
ent than any other metal bracket which is used tosupport and secure the power liftgate gear motor
assembly to the vehicles left rear body D-pillar.
The transverse bracket is a serviceable power lift-
gate component. Consult your MoparŸ parts catalog
for a specific part number.
OPERATION
The power liftgate transverse bracket supports the
gear motor assembly by supplying an additional
attachment point. Located on the leading edge of the
gear motor assembly, one end of the transverse
bracket attaches to the motor assembly the other to
the leading edge of the vehicles D-pillar.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the left D-pillar trim from the vehicle.
Refer to Body for the procedure.
(3) Disconnect the gear motor assembly electrical
connector and disengage retaining pushpin.
(4) Loosen the gear motor assembly retaining bolts
to allow room for transverse bracket to be removed.
(5) Remove the transverse bracket retaining bolts
(Fig. 10).
(6) Remove the transverse bracket from the vehi-
cle.
INSTALLATION
(1) Position the transverse bracket in the vehicle.
Be certain the transverse bracket is properly posi-
tioned. The bracket should just touch the engage
actuator arm and be positioned between the actuator
arm and the motor housing.
(2) Torque the transverse bracket retaining bolts
to the gear motor assembly to 9.5 N´m (85 in. lbs.)..
Do not tighten the transverse bracket retaining bolt,
located under the window actuator at this time.
(3) Torque the gear motor assembly retaining bolts
to 9.5 N´m (85 in. lbs.)..
(4) Torque the final transverse bracket retaining
bolt to 9.5 N´m (85 in. lbs.).
(5) Connect the gear motor assembly electrical con-
nector and engage retaining pushpin.
(6) Install the appropriate D-pillar trim from the
vehicle. Refer to Body for the procedure.
Fig. 9 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
RSPOWER LIFTGATE SYSTEM8N-13
ENGAGE ACTUATOR (Continued)

LIFT GEAR & LINK ROD
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
lift gear and rod assembly. This lift gear and rod
assembly are located in the left rear of the vehicle
and are visible without removing the D-pillar trim
(Fig. 10). The lift gear provides the leverage to move
the liftgate from the closed to the open position. The
lift gear attaches to a bearing on the gear motor
assembly with four bolts. On the outboard side of the
lift gear are rivited on teeth, which mesh with the
gear motor assembly drive gears during a open or
close operation. The rod assembly is a steel shaft,
equipped with two spherical rod ends which attaches
the lift gear to the liftgate.
The lift gear and rod assembly are serviceable com-
ponents. Consult your MoparŸ parts catalog for a
part number.
OPERATION
One end of the rod assembly is attached to the lift-
gate, the other attached to the lift gear. When the lift
gear is driven by the gear motor assembly the lift-
gate is moved to the open or closed position.
REMOVAL
(1) Remove the left rear D-pillar trim from the
vehicle. Refer to Body for the procedure.
(2) Remove the lift gear retaining bolts (Fig. 11).
(3) Remove the lift gear and rod from the vehicle.
INSTALLATION
(1) Position the lift gear assembly and install the
retaining bolts. Torque the bolts to 28 N´m (21 ft.
lbs.).
(2) Install the left rear D-pillar trim on the vehi-
cle. Refer to Body for the procedure.
CAUTION: Torque link rod to liftgate attachment
bolt to 250 in. lbs. Care must be taken not to over-
torque link rod bolt.
Fig. 10 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 11 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
8N - 14 POWER LIFTGATE SYSTEMRS

LATCH
DESCRIPTION
Vehicles equipped with a power liftgate, utilize a
power cinch/release latch. This latch performs the
same features as a manual liftgate latch as well as
the power cinch and / or release capability. A second
type of power latch can also be found on some RS
models, this latch is designed to perform a power
release only. The power cinch and release capability
is accomplished by an actuator mounted to the lead-
ing edge of the latch assembly. The latch is located in
the lower center of the liftgate assembly (Fig. 12) and
contains integral pawl and ratchet switches. The
ratchet switch acts as a liftgate ajar switch.
The power latch assembly can be serviced as a
complete assembly, latch without actuator or just the
actuator. Consult your Mopar parts catalog for spe-
cific part numbers.
OPERATION
On the power cinch/release latch, the latch
mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-
mary closed and latched position. On the power
cinch/release latch and the power release only latch,
the actuator releases the liftgate from the primary
closed and latched position to the fully unlatched and
movable position.
REMOVAL
(1) Open the hood, disconnect and isolate the neg-
ative battery cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 12).
(4) Remove the power latch retaining bolts.
(5) Disconnect the liftgate lock cylinder link rod
from the key cylinder or latch assembly. To discon-
nect from latch, rotate the plastic retaining clip 90 É
to unsnap clip from linkrod. Then pull link rod
straight out of latch arm.
INSTALLATION
(1) Connect the liftgate lock cylinder link rod on
the cinch latch assembly. Rotate the plastic retaining
clip 90 É to lock retaining clip on linkrod.
(2) Connect the link rod on the lock cylinder.
(3) Install the power latch retaining bolts. Torque
to 10 N´m (90 in. lbs.).
(4) Connect the power latch electrical connector
and secure push pin retainers.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the power latch.
(7) Verify power liftgate system and power cinch /
release latch operation. Cycle the power liftgate
through one complete open and close cycle, this will
allow the power liftgate control module to relearn its
cycle with the new components.
(8) Verify power liftgate manual operation. Using
liftgate key rotate the lock cylinder to verify door
operation. Pull door open using exterior liftgate han-
dle / switch.
(9) Install the liftgate trim panel. Refer to Body for
the procedure.Fig. 12 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
RSPOWER LIFTGATE SYSTEM8N-15