2002 CHRYSLER VOYAGER air conditioning

(5) Remove the drive belt (Fig. 11).
(6) Carefully return tensioner to its relaxed posi-
tion.
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 10).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
INSTALLATION
(1) Route and position the drive belt onto all pul-
leys, except for the crankshaft (Fig. 11).
(2) Rotate belt tensioner counterclockwise until
belt can be installed onto the crankshaft pulley (Fig.
9). Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys.
(4) Install drive belt shield (Fig. 8) and lower vehi-
cle.
Fig. 10 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
Fig. 11 ACCESSORY DRIVE BELT
1 - DRIVE BELT
2 - POWER STEERING PUMP PULLEY
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY
5 - GENERATOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY
7 - CRANKSHAFT PULLEY
8 - WATER PUMP PULLEY
RSACCESSORY DRIVE7-13
DRIVE BELTS - 3.3/3.8L (Continued)
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(6) Remove vapor purge solenoid from mounting
bracket.
(7) Disconnect upper and lower hoses from the
radiator (Fig. 13) or (Fig. 14).
(8) Remove the A/C condenser side brackets to
radiator attaching screws (Fig. 15). Separate the con-
denser from the radiator by lifting upward to disen-
gage from lower mounts (Fig. 15). Allow the
condenser to rest in front of radiator.
(9) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1)Be sure the air seal is in position before
radiator is installed.Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(2) Position air conditioning condenser onto the
radiator lower mounts and install upper screws (Fig.
15). Tighten fasteners to 5 N´m (45 in. lbs.).
(3) Install the radiator upper and lower hoses (Fig.
13) or (Fig. 14).
(4) Connect the coolant reserve/recovery hose.
(5) Connect the vapor purge solenoid to the mount-
ing bracket.
(6) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(7) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(8) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
(9) Connect negative cable to battery.
Fig. 13 Radiator Hoses to Radiator - 2.4L
1 - UPPER HOSE
2 - LOWER HOSE
3 - HOSE SUPPORT CLIP
Fig. 14 Radiator Hoses to Radiator - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 15 Radiator to A/C Condenser Mounting (left
mount shown, right similar)
1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR
2 - LOWER MOUNT
3 - A/C CONDENSER
7 - 26 ENGINERS
RADIATOR (Continued)
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COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE
READS LOW1. Diesel engines, due to their
inherent effiency are slower to warm
up than gasoline powered engines,
and will operate at lower
temperatures when the vehicle is
unloaded.1. The low gauge reading may
be normal. Refer to thermostats
in the manual text for
information. See Thermostat
Diagnosis-Diesel Engine.
2. Is the temperature gauge
connected to the temperature gauge
coolant sensor on the engine?2. Check, the engine
temperature sensor connector
in the engine compartment.
3. Is the temperature gauge
operating OK?3. Check gauge operation.
Repair as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with poor
heater performance.4. Check coolant level in the
coolant tank. Inspect system for
leaks. Repair leaks as
necessary. Refer to the Coolant
section for WARNINGS and
precautions before removing
the pressure cap.
5. Improper operation of internal
heater doors or heater controls.5. Inspect heater and repair as
necessary. Refer to Heating
and Air Conditioning for
procedures.
TEMPERATURE GAUGE
READS HIGH. COOLANT
MAY OR MAY NOT BE
LOST OR LEAKING FROM
COOLING SYSTEM1. Trailer is being towed, a steep hill
is being climbed, vehicle is operated
in slow moving traffic, or engine is
being idled with very high ambient
(outside) temperature and the air
conditioning is on. Higher altitudes
could aggravate these conditions.1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to
drive the vehicle without any of
the previous conditions.
Observe the temperature
gauge. The gauge should return
to the normal range. If the
gauge does not return to
normal range, determine the
cause for the overheating and
repair.
2. Temperature gauge reading
incorrectly.2. Check gauge. Refer to I/P
group.
3. Coolant low in coolant tank and
radiator.3. Check for coolant leaks and
repair as necessary.
4. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered.4. Tighten cap.
5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap
and cap seals. (b) Check
condition of coolant tank filler
neck. Make sure it does not
leak pressure.
7a - 2 COOLING 2.5L TURBO DIESELRG
COOLING 2.5L TURBO DIESEL (Continued)
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(8) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1)Be sure the air seal is in position before
radiator is installed.Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(2) Position air conditioning condenser onto the
radiator lower mounts and install upper screws (Fig.
12). Tighten fasteners to 5 N´m (45 in. lbs.).
(3) Install the radiator upper and lower hoses (Fig.
11).
(4) Connect the coolant bypass hose.
(5) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(6) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(7) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not recom-
mended. Damage may occur to radiator or drain-
cock.
NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.
(1) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(2) Open the draincock by turning it counterclock-
wise until it stops.
(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 13) from the radiator
tank.
INSTALLATION
(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
(3) Tighten the draincock by turning clockwise
until it stops.
(4) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
Fig. 12 Radiator to A/C Condenser Mounting (left
mount shown, right similar)
1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR
2 - LOWER MOUNT
3 - A/C CONDENSER
Fig. 13 Draincock
1 - RADIATOR TANK
2 - DRAINCOCK
7a - 22 ENGINERG
RADIATOR (Continued)
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(4) Remove the screw holding the PLG control
module to the D-pillar (Fig. 10).
(5) Remove the PLG control module from the vehi-
cle.
INSTALLATION
(1) Install the PLG control module on the D-pillar
and install retaining screw. Torque the screw to 14.5
in. lbs.
(2) Connect the wire harness connections on the
PLG control module. Be certain to slide connector
locks to the locked position.
(3) Install the D-pillar trim panel on the vehicle.
Refer to the Body section for the procedure.
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any PLG control module diagnostic trouble
codes.
(6) Verify PLG system operation. Cycle the PLG
through one complete open and close cycle, this will
allow the PLG control module to relearn its cycle
with the new components.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION
The Powertrain Control Module (PCM) is a digital
computer containing a microprocessor (Fig. 11). The
PCM receives input signals from various switches
and sensors referred to as Powertrain Control Mod-
ule Inputs. Based on these inputs, the PCM adjusts
various engine and vehicle operations through
devices referred to as Powertrain Control Module
Outputs.
NOTE: PCM Inputs:
²Air Conditioning Pressure Transducer
²ASD Relay
²Battery Voltage
²Brake Switch
²Camshaft Position Sensor
²Crankshaft Position Sensor
²Distance Sensor (from transmission control mod-
ule)
²EGR Position Feedback
²Engine Coolant Temperature Sensor
²Heated Oxygen Sensors
Fig. 10 LIFTGATE CONTROL MODULE
1 - POWER LIFTGATE CONTROL MODULE
2 - MODULE RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - MODULE ELECTRICAL CONNECTORS
Fig. 11 Powertrain Control Module (PCM)
1 - Battery
2 - Power Distribution Center
3 - Powertrain Control Module
RSELECTRONIC CONTROL MODULES8E-11
POWER LIFTGATE MODULE (Continued)
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²Ignition sense
²Intake Air Temperature Sensor
²Knock Sensor
²Leak Detection Pump Feedback
²Manifold Absolute Pressure (MAP) Sensor
²Park/Neutral (from transmission control module)
²PCI Bus
²Power Steering Pressure Switch
²Proportional Purge Sense
²SCI Receive
²Speed Control
²Throttle Position Sensor
²Torque Management Input (From TCM)
²Transaxle Control Module (TCM)
²Transaxle Gear Engagement (From TCM)
²Vehicle Speed (from transmission control mod-
ule)
NOTE: PCM Outputs:
²Air Conditioning Clutch Relay
²Automatic Shut Down (ASD) and Fuel Pump
Relays
²Data Link Connector (PCI and SCI Transmit)
²Double Start Override
²EGR Solenoid
²Fuel Injectors
²Generator Field
²High Speed Fan Relay
²Idle Air Control Motor
²Ignition Coils
²Leak Detection Pump
²Low Speed Fan Relay
²MTV Actuator
²Proportional Purge Solenoid
²SRV Valve
²Speed Control Relay
²Speed Control Vent Relay
²Speed Control Vacuum Relay
²8 Volt Output
²5 Volt Output
Based on inputs it receives, the powertrain control
module (PCM) adjusts fuel injector pulse width, idle
speed, ignition timing, and canister purge operation.
The PCM regulates the cooling fans, air conditioning
and speed control systems. The PCM changes gener-
ator charge rate by adjusting the generator field.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
²Battery Voltage
²Intake Air Temperature Sensor
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)²Exhaust Gas Oxygen Content (heated oxygen
sensors)
²Manifold Absolute Pressure
²Throttle Position
The PCM adjusts engine idle speed through the
idle air control motor based on the following inputs.
²Brake Switch
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
²Vehicle Speed (from Transmission Control Mod-
ule)
The PCM adjusts ignition timing based on the fol-
lowing inputs.
²Intake Air Temperature
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Knock Sensor
²Manifold Absolute Pressure
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
The automatic shut down (ASD) and fuel pump
relays are mounted externally, but turned on and off
by the powertrain control module through the same
circuit.
The camshaft and crankshaft signals are sent to
the powertrain control module. If the PCM does not
receive both signals within approximately one second
of engine cranking, it deactivates the ASD and fuel
pump relays. When these relays are deactivated,
power is shut off to the fuel injectors, ignition coils,
fuel pump and the heating element in each oxygen
sensor.
The PCM contains a voltage converter that
changes battery voltage to a regulated 8.0 volts. The
8.0 volts power the camshaft position sensor, crank-
shaft position sensor and vehicle speed sensor. The
PCM also provides a 5.0 volts supply for the engine
coolant temperature sensor, intake air temperature
sensor, manifold absolute pressure sensor and throt-
tle position sensor.
The PCM engine control strategy prevents reduced
idle speeds until after the engine operates for 320 km
(200 miles). If the PCM is replaced after 320 km (200
miles) of usage, update the mileage in new PCM. Use
the DRB scan tool to change the mileage in the PCM.
Refer to the appropriate Powertrain Diagnostic Man-
ual and the DRB scan tool.
8E - 12 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
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PCM/SKIM PROGRAMMING
When a PCM (JTEC) and the SKIM are replaced
at the same time perform the following steps in
order:
(1) Program the new PCM (JTEC)
(2) Program the new SKIM
(3) Replace all ignition keys and program them to
the new SKIM.
ECM/SKIM PROGRAMMING
When an ECM (Bosch) and the SKIM are replaced
at the same time perform the following steps in
order:
(1) Program the new SKIM
(2) Program the new ECM (Bosch)
PROGRAMMING THE ECM (Bosch)
(1) To program the VIN, connect the DRB III and
turn the ignition on.
(2) Select Engine from the main menu. The DRB
III will require the VIN to be entered before continu-
ing.
(3) Select ENTER to update the VIN. The DRB III
will display the updated VIN.
(4) If the engine is equipped with air conditioning,
the ECM A/C function must be enabled. Enable the
ECM A/C function as follows:
²Using the DRB III select ENGINE, MISCELLA-
NEOUS, then ENABLE/DISABLE A/C
²Push 1 to enable A/C. DRB III screen should dis-
play A/C Activated.
PROGRAMMING THE PCM (JTEC)
The SKIS Secret Key is an ID code that is unique
to each SKIM. This code is programmed and stored
in the SKIM, PCM and transponder chip (ignition
keys). When replacing the PCM it is necessary to
program the secret key into the new PCM using the
DRB III. Perform the following steps to program the
secret key into the PCM.
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
(5) Select ENTER to update PCM VIN.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition to the RUN
position for one hour then enter the correct PIN.
(Ensure all accessories are turned off. Also monitorthe battery state and connect a battery charger if
necessary).
(6) Press ENTER to transfer the secret key (the
SKIM will send the secret key to the PCM).
(7) Press Page Back to get to the Select System
menu and select ENGINE, JTEC (diesel only), MIS-
CELLANEOUS, and SRI MEMORY CHECK.
(8) The DRB III will ask, Is odometer reading
between XX and XX? Select the YES or NO button on
the DRB III. If NO is selected, the DRB III will read,
Enter odometer Reading. Enter
the odometer reading from the Instrument Panel and
press ENTER.
PROGRAMMING THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Program the vehicle four-digit PIN into SKIM.
(5) Select COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, the SKIM must be replaced.
(6) Select YES to update VIN (the SKIM will learn
the VIN from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM will send the secret key to the SKIM).
(8) Program ignition keys to SKIM.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle keys will need to be replaced
and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PROGRAM IGNITION KEY'S.
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
If ignition key programming is unsuccessful, the
DRB III will display one of the following messages:
Programming Not Attempted - The DRB III
attempts to read the programmed key status and
there are no keys programmed into SKIM memory.
RGELECTRONIC CONTROL MODULES8Ea-3
ENGINE CONTROL MODULE (Continued)
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WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1MESSAGE CENTER................... 8W-46-1
AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION SYSTEM........ 8W-97-1 RSWIRING
8W-1
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