2004 CHRYSLER VOYAGER windshield wipers

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fuel additives oil type wheel radio instrument panel clock

Page 329 of 2585

CHRYSLER VOYAGER 2004 Service Manual (2) Install clutch release bearing to lever. Apply
grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 10).
(3) Apply grease to pivot ball, and on rel

Page 330 of 2585

CHRYSLER VOYAGER 2004 Service Manual INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into das

Page 331 of 2585

CHRYSLER VOYAGER 2004 Service Manual (10) Using Tool 6638A, disconnect clutch master
cylinder ªquick connectº fitting (Fig. 17). Disengage
plumbing retainer from body stud.
(11) Remove master cylinder reservoir-to-strut
tower nuts (Fig

Page 537 of 2585

CHRYSLER VOYAGER 2004 Service Manual LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power and high
side drivers source, ON/OFF device, lamps an

LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power and high
side drivers source, ON/OFF device, lamps and body
grounds to operate properly. Plastic lamps require a
wire in the harness to supply body ground to the
lamp socket. Replace sockets and bulbs that are cor-
roded.
Some of the interior and exterior lighting functions
are governed by the Body Control Module (BCM).
The headlamp, dome, and the door ajar switches pro-
vide signals to the BCM. The BCM in turn sends a
Programmable Communication Interface (PCI) bus
message to the Front Control Module (FCM) to
enable the necessary drivers to set the required illu-
mination configuration.
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors,
inspect the terminals inside the connector. Male ter-
minals should not be bent or disengaged from the
insulator. Female terminals should not be sprung
open or disengaged from the insulator. Bent and
sprung terminals can be repaired using needle nose
pliers and pick tool. Corroded terminals appear
chalky or green. Corroded terminals should be
replaced to avoid recurrence of the problem symp-
toms.
Begin electrical system failure diagnosis by testing
related fuses in the fuse block and intelligent power
module. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to the
appropriate wiring information.
AUTOMATIC HEADLAMP SYSTEM
The Automatic Headlamp system turns the instru-
mentation and exterior illumination lamps ON when
the ambient light levels are Night and the engine
RPM is 450 or above, and OFF when light levels are
Day.
DAYTIME RUNNING LAMPS
Operating the high-beam headlamps at reduced
power provides daytime running lamps, which are
required on all new Canadian vehicles. Daytime run-
ning lamps are functional when 450 rpm's are
reached.
HEADLAMPS ON WITH WINDSHIELD WIPERS
For vehicles equipped with the Automatic Head-
lamp System, the instrumentation and exterior illu-
mination lamps will be turned ON when the
headlamp switch is in the AUTO position, RPM >450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
if the instrumentation and exterior illumination
lamps should remain ON base upon the current
ambient light level.
HEADLAMP SYSTEM
The configuration of the headlamp system of head-
lamps, park lamps and fog lamps is determined by
the BCM. The BCM determines the lighting configu-
ration as a result of the inputs from the ignition
switch, headlamp switch and multi-function switch. A
PCI bus is transmitted from the BCM to the FCM to
enable the necessary drivers to set the illumination
configuration. Four wires are connected between the
headlamp switch and the BCM. The first wire con-
tains information regarding the position of the head-
lamp switch (Off, Automatic Headlamps, Automatic
Headlamp switch fog, Park with Fog, Head, or Head
with Fog Lamps). The second wire contains informa-
tion regarding the position of the dimmer switch
(Dome Lamp, Daytime Brightness, Dimming Level or
Off). The third wire is a dedicated signal return
(ground) wire. The fourth wire provides power to the
front fog lamp indicator.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is controlled by
the Body Control Module (BCM) via a PCI bus mes-
sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body
Control Module (BCM). With the headlamp switch in
the AUTO position, the BCM will control the head-
lamp, parking, side marker, tail and instrumentation
lamps based on ambient light levels. Ambient light
levels are monitored by the BCM using the Day/
Night signal and Electrochromatic Mirror (ECM)
present from the Compass Mini Trip (CMTC) located
on the front windshield in front of the rear view mir-
ror ECM. Ambient light readings are averaged to
limit cycling the lamps ON and OFF when passing
through areas with varying light levels. The auto-
matic headlamps will only function when the engine
is running with RPM > 450. When the headlamp
switch is in the AUTO position (Automatic mode), the
Headlamp Time Delay system will function when the
ignition switch is placed in any position other than
run/start.
8L - 2 LAMPS/LIGHTING - EXTERIORRS

Page 568 of 2585

CHRYSLER VOYAGER 2004 Service Manual with the optional Auto Headlamps. The options
include Yes and No. The default is No. When Yes is
selected, the headlamps will turn on automatically
when the windshield wipers are turned on. The head-

with the optional Auto Headlamps. The options
include Yes and No. The default is No. When Yes is
selected, the headlamps will turn on automatically
when the windshield wipers are turned on. The head-
lamps will turn off when the wipers are turned off,
as long as the headlamp switch is in the Auto or Off
positions. When No is selected, the headlamps will
only turn on if manually selected or if the Auto mode
is selected and the outside ambient light levels dic-
tate that they should be on.
²RETRAIN TIRE SENSORS?- This program-
mable feature only applies to vehicles equipped with
the optional Tire Pressure Monitoring System. The
options include Yes and No. The default is No. When
Yes is selected, and the menu button is depressed the
EVIC will enter the training mode, starting with the
left front tire.
²POWER ACCESSORY DELAY?- The options
include Yes and No. The default is Yes. When No is
selected, the accessory powered components will turn
off automatically when the ignition key is turned off.
When Yes is selected, the accessory powered compo-
nents will remain on for 45 seconds when the igni-
tion key is turned off.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove overhead console. Refer to Overhead
Console Removal and Installation in this section(Re-
fer to 8 - ELECTRICAL/OVERHEAD CONSOLE -
REMOVAL).
(3) Remove the ten screws holding the EVIC mod-
ule in the overhead console.
(4) Remove EVIC module from console assembly.
NOTE: If the EVIC module is being replaced, the tire
pressure monitoring system (if equipped) must be
retrained. Refer to the Tires/Wheels section of this
manual for detailed instructions.
INSTALLATION
(1) Position the EVIC module in the overhead con-
sole.
(2) Install the ten screws holding the EVIC module
in the overhead console.
(3) Install the overhead console (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - INSTALLA-
TION).
(4) Connect the battery negative cable.
NOTE: If the EVIC module is being replaced, the tire
pressure monitoring system (if equipped) must be
retrained. Refer to the Tires/Wheels section of this
manual for detailed instructions.NOTE: If a new EVIC module has been installed, the
compass will have to be calibrated and the variance
set. Refer to compass variation adjustment and
compass calibration in standard procedures.
COMPASS/MINI-TRIP
COMPUTER
DESCRIPTION
The Compass Mini-Trip Computer (CMTC) and
Compass Temperature (CT) computer are modules
located in the overhead console. Vehicles are
equipped with either the CMTC or the CT computers
not both. The CMTC is different in the fact that it is
equipped with the mini-trip feature. The CMTC, CT
consists of a electronic control module with a vacuum
fluorescent display (VFD) and function switches. The
CMTC, CT consists of a electronic module that dis-
plays compass, trip computer (CMTC only), and tem-
perature features. Actuating the STEP push button
(CMTC only) will cause the CMTC to change mode of
operation when ignition is ON. Actuating the STEP
push button (CMTC only) will cause the CMTC to
change mode of operation when ignition is ON.
Example:
²Average miles per gallon (ECO)
²Distance to empty (DTE)
²Instant miles per gallon (ECO)
²Trip odometer (ODO)
²Elapsed time (ET)
²Off
Actuating the C/T push button will cause the
CMTC, CT to change to Compass/Temperature dis-
play.
OPERATION
The Compass Mini-Trip Computer (CMTC), Com-
pass Temperature (CT) module in the overhead con-
sole has buttons used to select various functions. The
CMTC, CT selector buttons will not operate until the
ignition is in the RUN position.
When the ignition switch is first turned to the
RUN position the CMTC, CT display;
²Blanks momentarily
²All segments of the VFD will light for one sec-
ond
²Blanks momentarily
²Returns to the last mode setting selected before
the ignition was last switched OFF.
RSMESSAGE SYSTEMS8M-9
ELECTRONIC VEHICLE INFO CENTER (Continued)

Page 688 of 2585

CHRYSLER VOYAGER 2004 Service Manual WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER
SYSTEM

WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER
SYSTEM.............................2
DIAGNOSIS AND TESTING - FRONT
WIPER/WASHER SWITCH................2
DIAGNOSIS AND TESTING - FAILED PARK
SWITCH.............................2
DIAGNOSIS AND TESTING - REAR WIPER
SYSTEM.............................4
DIAGNOSIS AND TESTING - WASHER
SYSTEM.............................4
FRONT WASHER PUMP MOTOR
REMOVAL.............................8
INSTALLATION..........................8
FRONT WIPER ARMS
STANDARD PROCEDURE - FRONT WIPER
ARM ALIGNMENT......................8
REMOVAL.............................9
INSTALLATION..........................9
FRONT WIPER MOTOR
REMOVAL.............................9
INSTALLATION..........................9
REAR WASHER PUMP MOTOR
REMOVAL.............................10
INSTALLATION.........................10REAR WIPER ARM
REMOVAL.............................10
INSTALLATION.........................10
REAR WIPER MOTOR
REMOVAL.............................11
INSTALLATION.........................11
REAR WIPER/WASHER SWITCH
DESCRIPTION.........................11
OPERATION...........................11
WASHER FLUID LEVEL SWITCH
REMOVAL.............................12
INSTALLATION.........................12
WASHER HOSES
REMOVAL.............................13
INSTALLATION.........................13
WASHER RESERVOIR
REMOVAL.............................13
INSTALLATION.........................13
WIPER BLADES
REMOVAL.............................14
CLEANING............................14
INSTALLATION.........................14
WIPER LINKAGE
REMOVAL.............................14
INSTALLATION.........................14
WIPER MODULE
REMOVAL.............................15
INSTALLATION.........................15
WIPERS/WASHERS
DESCRIPTION
FRONT WIPER/WASHER SYSTEM
The windshield wipers can be operated with the
windshield wiper switch when the ignition switch is
in the RUN or ACCESSORY positions. The wind-
shield wiper system is protected by a 30 amp fuse (9)
located in the Power Distribution Center (PDC) part
of the Integrated Power Module (IPM) in the engine
compartment. The wiper/washer switch is integral to
the multi-function switch. It is a resistive MUX
switch that sends inputs to the BCM to operate the
wiper/washer system.
REAR WIPER/WASHER SYSTEM
The rear windshield wiper and washers can be
operated when the ignition switch is in the RUN
position.
If equipped with Manual Temperature Controls
(MTC), the rear wiper/washer switch is integral to
the HVAC control unit. It replaces what was formerly
the ON/OFF switch. If equipped with Automatic Tem-
perature Controls (ATC), the rear wiper/washer
switch is located on the accessory switch panel in the
center stack of the instrument panel.
OPERATION
FRONT WIPER/WASHER SYSTEM
The windshield washer circuit is protected by a 15
amp Cartridge Fuse located in the IPM. The wiper
motor has permanent magnetic fields. The speeds are
determined by current flow to the appropriate set of
RSWIPERS/WASHERS8R-1

Page 689 of 2585

CHRYSLER VOYAGER 2004 Service Manual brushes inside the motor. The current flow is con-
trolled by the multi-function switch. The high speed/
low speed relays are located in the IPM. The speed
sensitive intermittent wiper is controlled b

brushes inside the motor. The current flow is con-
trolled by the multi-function switch. The high speed/
low speed relays are located in the IPM. The speed
sensitive intermittent wiper is controlled by the Body
Control Module (BCM). The intermittent mode, with
the vehicle traveling greater than 10.4 mph, has a
range of 0.5 to 18 seconds. With the vehicle traveling
less than 10.4 mph, the time delay doubles to a
range of 1 to 36 seconds. The wiper arms will park at
the base of the windshield just above the cowl cover
after the wiper switch is turned OFF.
The windshield wiper motor and linkage is located
in an integral wiper unit at the rear of the engine
compartment. The wiper unit must be removed to
gain access to the wiper motor.
REAR WIPER/WASHER SYSTEM
When rear wiper operation is required, the BCM
will provide ignition ON voltage to the rear wiper
motor (Export and ATC equipped vehicles only).
When the wiper switch is turned OFF, the BCM pro-
vides circuit ground to operate the motor until the
wipe cycle is complete and the wiper arm returns to
the base of the rear window.
Switch only offers an intermittent rear wiper
mode. The wiper motor will cycle every 7 seconds.
The intermittent delay time is also adjusted based
upon vehicle speed. With the vehicle traveling
greater than 50 mph, the cycle changes to every 5
seconds.
When rear washer is requested by depressing and
holding down the switch, the BCM then provides a
ground for the rear washer motor. Until the switch is
released, the motor will be in a continuous wipe
mode, then return to an intermittent wipe mode.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER
SYSTEM
The windshield wiper system operates in several
modes:
²Low and high speed normal wipe
²Speed sensitive intermittent wipe
²Wipe after wash
²Park (switch OFF)
The windshield wiper circuits are continuously
monitored and controlled by the Body Control Mod-
ule (BCM). If a problem occurs in the electronic com-
ponents, wiring, switch (except integral motor park
switch) and wiper motor a Diagnostic Trouble Code
(DTC) will be stored in the BCM memory. DTC's can
be retrieved using a DRB IIItscan tool. Refer to the
proper Body Diagnostic Procedures manual for DTC
descriptions and retrieval information.The windshield wiper park switch and circuit is
monitored by the BCM. The park switch and circuit
can be tested using the Wiper System Diagnosis
table.
DIAGNOSIS AND TESTING - FRONT
WIPER/WASHER SWITCH
(1) Remove the multi-function switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
MULTI-FUNCTION SWITCH - REMOVAL).
(2) Using an ohmmeter check resistance readings
between switch pins. Refer to the WIPER/WASHER
SWITCH RESISTANCE table.
WIPER/WASHER SWITCH RESISTANCE
SWITCH POSITION RESISTANCE BETWEEN
OFF 1 AND 2 = 23.9KV 5%
DELAY POSITION
1ST 1 AND 2 = 7.9KV 5%
2ND 1 AND 2 = 4.6KV 5%
3RD 1 AND 2 = 2.9KV 5%
4TH 1 AND 2 = 1.9KV 5%
5TH 1 AND 2 = 1.3KV 5%
LOW 1 AND 2 = 670V 5%
HIGH 1 AND2=240V 5%
WASH 1 AND 4 = 5.9KV 5%
DIAGNOSIS AND TESTING - FAILED PARK
SWITCH
If the wiper park switch has failed, the windshield
wipers will operate as follows:
²SWITCH OFF- Wipers stop in current location
regardless of the park signal.
²INTERMITTENT MODE- Wipers operate con-
tinuously or at low speed for one or more extra
wipes.
²LOW SPEED- Wipers operate at low speed.
²HIGH SPEED- Wipers operate at high speed.
²WIPE AFTER WASH- Wipers operate at low
speed in any mode setting. Wipers operate only while
the wash button is depressed with switch in the OFF
mode and wipers stop in mid-cycle when button is
released.
The windshield wiper park switch and circuit is
monitored by the BCM. The park switch and circuit
can be tested using the WIPER SYSTEM DIAGNO-
SIS table.
8R - 2 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)

Page 691 of 2585

CHRYSLER VOYAGER 2004 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
WIPER MOTOR WILL NOT
RUN1. BLOWN FUSE. 1. REPLACE FUSE, AND RUN SYSTEM.
2. NEW FUSE BLOWS. 2. CHECK FOR SHORT IN WIRING OR
SWITCH.
3. NEW FUSE BLOWS. 3. REPLACE FU

CONDITION POSSIBLE CAUSES CORRECTION
WIPER MOTOR WILL NOT
RUN1. BLOWN FUSE. 1. REPLACE FUSE, AND RUN SYSTEM.
2. NEW FUSE BLOWS. 2. CHECK FOR SHORT IN WIRING OR
SWITCH.
3. NEW FUSE BLOWS. 3. REPLACE FUSE, REMOVE MOTOR
CONNECTOR, TURN SWITCH ON, FUSE
DOES NOT BLOW, REPLACE MOTOR.
4. NO VOLTAGE AT MOTOR. 4. CHECK SWITCH AND WIRING
HARNESS. REFER TO WIRING
DIAGRAMS.
5. POOR GROUND. 5. REPAIR GROUND WIRE CONNECTION
AS NECESSARY.
DIAGNOSIS AND TESTING - REAR WIPER
SYSTEM
The rear window wiper system operates in several
modes:
²Continuous wipe (Export and ATC equipped
vehicles only)
²Intermittent wipe
²Wash²Wipe after wash
The windshield wiper circuits are continuously
monitored and controlled by the Body Control Mod-
ule (BCM). If a problem occurs in the electronic com-
ponents, wiring, switch (except integral motor park
switch) and wiper motor a Diagnostic Trouble Code
(DTC) will be stored in the BCM memory. The
DTC(s) can be retrieved using a DRB IIItscan tool.
DIAGNOSIS AND TESTING - WASHER SYSTEM
WASHER SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
WASHER MOTOR 1. IPM FUSE #33 BLOWN OR
DEFECTIVE.1. CHECK FUSE #33 IN THE IPM. REPLACE
IF NOT OK.
2. IPM FUSE #33 LOOSE. 2. PROPERLY INSTALL IPM FUSE #33 IN
SOCKET.
BLOWN FUSE WHEN
IGNITION SWITCH IS IN THE
RUN OR ACCESSORY
POSITION.1. SHORT IN IPM BETWEEN
FUSE #33 AND PIN 11 OR PIN 1.1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. SHORT IN MOTOR POWER
CIRCUIT.2. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 11 AND WASHER MOTOR
CONNECTOR POSITIVE TERMINAL 2. IF NOT
OK, REPAIR CIRCUIT.
3. SHORT IN WASHER PUMP
MOTOR.3. REPLACE WASHER PUMP MOTOR.
WASHER MOTOR RUNS
WHEN IGNITION SWITCH IN
RUN OR ACCESSORY
POSITION.1. SHORT IN IPM BETWEEN
WASHER PUMP MOTOR LSD
AND PIN 20.1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. DEFECTIVE FRONT WASHER
LSD IN IPM.2. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
3. SHORT IN MOTOR GROUND
CIRCUIT.3. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 20 AND MOTOR
CONNECTOR NEGATIVE TERMINAL 1. IF
NOT OK, REPAIR CIRCUIT.
8R - 4 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)

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