2002 CHRYSLER VOYAGER body code

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION..........................1
FASTENER IDENTIFICATION
DESCRIPTION..........................2
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE........5
DESCRIPTION - THREADED HOLE REPAIR . . 5
INTERNATIONAL SYMBOLS
DESCRIPTION..........................5
METRIC SYSTEM
DESCRIPTION..........................6TORQUE REFERENCES
DESCRIPTION..........................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION..........................9
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION.........................11
E-MARK LABEL
DESCRIPTION.........................11
VECI LABEL
DESCRIPTION.........................11
MANUFACTURER PLATE
DESCRIPTION.........................11
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.
BODY CODE PLATE ± LINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13 THROUGH 17
Open Space
DIGITS 18 AND 19
Vehicle Shell Line
²RS
DIGIT 20
Carline
FWD
²K = Dodge
²Y = Chrysler
AW D
²C = Chrysler
²D = Dodge
Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - VINYL ROOF
4 - VEHICLE ORDER NUMBER
5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
8 - TRIM
9 - TRANSMISSION
10 - MARKET
11 - VIN
RSINTRODUCTION1
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DIGIT 21
Price Class
²H = Highline
²L = Lowline
²P = Premium
²S = Luxury
²X = Premium
DIGITS 22 AND 23
Body Type
²52 = Short Wheel Base
²53 = Long Wheel Base
BODY CODE PLATE LINE 2
DIGITS 1, 2 AND 3
Paint Procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary Paint (Refer to 23 - BODY/PAINT - SPEC-
IFICATIONS).
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline
(MPI)
²EGA = 3.3L 6 cyl. Gasoline (SMPI)
²EGH = 3.8L 6 cyl. Gasoline (SMPI)
²EGM = 3.3L 6 cyl. Ethanol Flexible Fuel
²ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel
DIGIT 23
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGC = 31TH 3-Speed Automatic Transaxle
²DGL = 41AE/TE 4-Speed Electronic Automatic
²DDR = T850 5-Speed Manual Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
²C = Canada
²B = International
²M = Mexico
²U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
²Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
2 INTRODUCTIONRS
BODY CODE PLATE (Continued)
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POSITION INTERPRETATION CODE = DESCRIPTION
6 Series 2 = Low Line
4 = High Line
5 = Premium
6 = Sport
7 = Special
6 - Export Series B = 4-Speed Automatic Transaxle
N = 5-Speed Manual Transaxle
7 Body Style 4 = Long Wheel Base
5 = Short Wheel Base
7 - Export Body Style 1 = EURO Wagon-Long Wheelbase RG-53-S Series
2 = EURO Wagon-Short Wheelbase RG-52-H Series
3 = EURO Wagon-Short Wheelbase RG-52-P Series
4 = EURO Wagon-Long Wheelbase RG-53-P Series
5 = EURO Wagon-Long Wheelbase RG-53-H Series
6 = Comercial Van-Short Wheelbase with-CYX Less AS8
7 = Comercial Van-Short Wheelbase with AS8
8 = Comercial Van-Long Wheelbase Highline with-CYX
9 = Comercial Van-Long Wheelbase Premium Line
with-CYX
CYX = No Rear Seat Package
AS8 = Interior Delete Group
8 Engine B = 2.4L 4 cyl. 16-Valve Gasoline DOHC (MPI)
L = 3.8L 6 cyl. Gasoline (SMPI)
R = 3.3L 6 cyl. Gasoline (SMPI)
3 = 3.3L 6 cyl. Enthanol Flex Fuel
7 = 2.5L 4 cyl. 16 Valve Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 2= 2002
11 Assembly Plant B = St. Louis Assembly South
R = Windsor Assembly
U = Graz Assembly
12 through 17 Sequence Number A six digit number assigned by assembly plant.
10 INTRODUCTIONRS
VEHICLE IDENTIFICATION NUMBER (Continued)
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(27) Install lower steering column cover/knee
blocker (Fig. 62).
(28) Install silencer panel below lower steering col-
umn cover/knee blocker.
NOTE: When reconnecting the battery on a vehicle
that has had the airbag module removed, the fol-
lowing procedure should be used.
(29) Reconnect ground cable to negative post of
battery in following manor:
(a) Connect scan tool (DRBIIIt) to data link
diagnostic connector located below steering column.
(b) Turn ignition key to ON position. Exit vehi-
cle with scan tool leaving scan tool harness
plugged in.
(c) Ensuring that there are no occupants in vehi-
cle, connect ground (-) cable to the negative post of
the battery.
(d) Using scan tool, read and record any airbag
fault codes. Refer to Appropriate Diagnostic Infor-
mation if any faults are found.
(e) Through drivers open window, Reach around
back of steering wheel (between steering wheel and
instrument cluster) and turn ignition key to OFF,
then back ON while observing instrument cluster
airbag indicator lamp. It should go on for six to
eight seconds, then go out. This action indicates
that airbag system is functioning normally. If air-
bag indicator lamp fails to light, blinks on and off,
or goes on and stays on, there is an airbag system
malfunction. Refer to Appropriate Diagnostic Infor-
mation to diagnose the system malfunction.
(30) Using scan tool (DRBIIIt), check for and clear
any existing adjustable pedal fault codes. The adjust-
able pedal system is now activated.
(31) Turn key to OFF and remove scan tool from
vehicle.
(32) Test operation of adjustable pedals, memory
seats (if equipped), RKE (if equipped), and all func-
tions that are steering column operated. If applica-
ble, reset the radio and the clock.
(33) Road test the vehicle to ensure proper opera-
tion of the steering and brake systems.
PEDAL TORQUE SHAFT - RHD
REMOVAL
(1) Remove the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(2) Remove the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL)
(3) Remove the retaining clip at the torque shaft
end of the brake pedal-to-torque shaft link. Removethe link from the torque shaft. Discard the retaining
clip. It is not to be reused. Replace with a new clip
when reassembled.
(4) Locate the booster input rod-to-brake pedal
torque shaft connection and remove the retaining clip
(Fig. 73). Discard the retaining clip. It is not to be
reused. Replace with a new clip when reassembled.
(5) Remove the four (4) brake booster retaining
nuts from inside the passenger compartment (Fig.
74).
(6) Remove the retaining nut from the brake
booster bracket located above the booster in the
engine compartment (Fig. 74).
(7) Remove the power brake booster bracket.
(8) Rotate the pedal torque shaft and remove it out
the left side of the vehicle.
INSTALLATION
(1) Lubricate both ends of the torque shaft with
MS-4517 Lubricant or equivalent and install the
torque shaft from the left side reversing the removal
procedure.
(2) Install the brake booster bracket on the left
end of the shaft.
(3) Install the four brake booster retaining nuts
inside the passenger compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(4) Install the retaining nut for the brake booster
bracket in the engine compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(5) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal torque shaft pin where it con-
tacts the booster input rod. Also coat the surface of
Fig. 73 POWER BRAKE BOOSTER BRACKET
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT
3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
RSBRAKES - BASE5-47
PEDAL - ADJUSTABLE (Continued)
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ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING.......................2
ADJUSTABLE PEDAL MODULE
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL MODULE.......................3
REMOVAL.............................3
INSTALLATION..........................3
BODY CONTROL MODULE
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................5
INSTALLATION..........................5
CONTROLLER ANTILOCK BRAKE
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................6
INSTALLATION..........................6
DATA LINK CONNECTOR
DESCRIPTION..........................7
OPERATION............................7
FRONT CONTROL MODULE
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE....................8
REMOVAL.............................8
INSTALLATION..........................8
HEATED SEAT MODULE
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE.............................9
REMOVAL.............................10
INSTALLATION.........................10
POWER LIFTGATE MODULE
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................11
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION........................11DIAGNOSTIC TROUBLE CODE...........13
OPERATION - SENSOR RETURN - PCM
INPUT..............................25
OPERATION - SCI RECEIVE - PCM INPUT . . 25
OPERATION - IGNITION SENSE - PCM
INPUT..............................25
OPERATION - PCM GROUND............25
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM
OUTPUT............................25
OPERATION - 5 VOLT SUPPLY - PCM
OUTPUT............................25
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES..........25
REMOVAL.............................26
INSTALLATION.........................26
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION.........................26
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................27
TRANSMISSION CONTROL MODULE
DESCRIPTION.........................28
OPERATION...........................28
STANDARD PROCEDURE
STANDARD PROCEDURE - PINION
FACTOR SETTING.....................31
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE........................31
REMOVAL.............................31
INSTALLATION.........................32
MEMORY SEAT/MIRROR MODULE
DESCRIPTION.........................33
OPERATION...........................33
DIAGNOSIS AND TESTING - MEMORY
SEAT/MIRROR MODULE................33
REMOVAL.............................33
INSTALLATION.........................33
SLIDING DOOR CONTROL MODULE
DESCRIPTION.........................33
OPERATION...........................34
REMOVAL.............................34
INSTALLATION.........................34
RSELECTRONIC CONTROL MODULES8E-1
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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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(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P1683 SPD CTRL PWR Relay; or S/C 12v
Driver CKTAn open or shorted condition detected in the speed control
servo power control circuit. (SBECII: ext relay).
P1684 Battery Loss In The Last 50 Starts The battery has been disconnected within the last 50 starts.
P1685 Skim Invalid Key The engine controller has received an invalid key from the
SKIM.
P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).
P1687 No MIC BUS Message No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.
P1693 DTC Detected in Companion Module A fault has been generated in the companion engine control
module.
P1694 Fault In Companion Module No CCD/J1850 messages received from the powertrain
control module-Aisin transmission.
P1695 No CCD/J1850 Message From Body
Control ModuleNo CCD/J1850 messages received from the body control
module.
P1696 (M) PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the
control module.
P1697 (M) PCM Failure SRI Mile Not Stored Unsuccessful attempt to update Service Reminder Indicator
(SRI or EMR) mileage in the control module EEPROM.
P1698 (M) No CCD/J1850 Message From TCM No CCD/J1850 messages received from the electronic
transmission control module (EATX) or the Aisin transmission
controller.
P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission
2-3 gear lock-out solenoid control circuit.
P1740 TCC or O/D Solenoid Performance Rationality error detected in either the torque convertor
clutch or solenoid or overdrive solenoid system.
P1756 GOV Press Not Equal to Target @
15-20 PSIThe requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control shifts
for 1st, 2nd, and 3rd gear. (Mid Pressure Malfunction)
P1757 GOV Press Not Equal to Target @
15-20 PSIThe requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control shifts
for 1st, 2nd, and 3rd gear (Zero Pressure Malfunction)
P1762 Gov Press Sen Offset Volts Too Low
or HighThe Governor Pressure Sensor input is greater than a
calibration limit or is less than a calibration limit for 3
consecutive park/neutral calibrations.
P1763 Governor Pressure Sensor Volts Too
HiThe Governor Pressure Sensor input is above an acceptable
voltage level.
P1764 Governor Pressure Sensor Volts Too
LowThe Governor Pressure Sensor input is below an acceptable
voltage level.
P1765 Trans 12 Volt Supply Relay CTRL
CircuitAn open or shorted condition is detected in the Transmission
Relay control circuit. This relay supplies power to the TCC
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch.
8E - 24 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
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(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P2008 Short Runner Valve Solenoid Circuit An open or shorted condition detected in the short runner
tuning valve control circuit.
P2302 Ignition Coil Secondary #1 Circuit
P2305 Ignition Coil Secondary #2 Circuit
P2308 Ignition Coil Secondary #3 Circuit
P2311 Ignition Coil Secondary #4 Circuit
P2314 Ignition Coil Secondary #5 Circuit
P2317 Ignition Coil Secondary #6 Circuit
P2320 Ignition Coil Secondary #7 Circuit
P2323 Ignition Coil Secondary #8 Circuit
P2503 Charging System Voltage Low Charging system voltage below minimum acceptable voltage.
OPERATION - SENSOR RETURN - PCM INPUT
The sensor return circuit provides a low electrical
noise ground reference for all of the systems sensors.
The sensor return circuit connects to internal ground
circuits within the Powertrain Control Module (PCM).
OPERATION - SCI RECEIVE - PCM INPUT
SCI Receive is the serial data communication
receive circuit for the DRB scan tool. The Powertrain
Control Module (PCM) receives data from the DRB
through the SCI Receive circuit.
OPERATION - IGNITION SENSE - PCM INPUT
The ignition sense input informs the Powertrain
Control Module (PCM) that the ignition switch is in
the crank or run position.
OPERATION - PCM GROUND
Ground is provided through multiple pins of the
PCM connector. Depending on the vehicle there may
be as many as three different ground pins. There are
power grounds and sensor grounds.
The power grounds are used to control the ground
side of any relay, solenoid, ignition coil or injector.
The signal ground is used for any input that uses
sensor return for ground, and the ground side of any
internal processing component.
The SBEC III case is shielded to prevent RFI and
EMI. The PCM case is grounded and must be firmly
attached to a good, clean body ground.
Internally all grounds are connected together, how-
ever there is noise suppression on the sensor ground.
For EMI and RFI protection the case is also
grounded separately from the ground pins.
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM OUTPUT
The PCM supplies 8 volts to the crankshaft posi-
tion sensor, camshaft position sensor.
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
The PCM supplies 5 volts to the following sensors:
²A/C pressure transducer
²Engine coolant temperature sensor
²Manifold absolute pressure sensor
²Throttle position sensor
²Linear EGR solenoid
²Battery temperature
²Knock sensor
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES
BULB CHECK
Key on: Bulb illuminated until vehicle starts, as
long as all once per trip (readiness) monitors com-
pleted. If monitors havenotbeen completed, then:
Key on: bulb check for about 8 seconds, lamp then
flashes if once per trip (readiness) monitors havenot
been completed until vehicle is started, then MIL is
extinguished.
OBTAINING DTC'S USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
RSELECTRONIC CONTROL MODULES8E-25
POWERTRAIN CONTROL MODULE (Continued)
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