2004 CHRYSLER VOYAGER air condition

FRONT FOG LAMP
DIAGNOSIS AND TESTING - FRONT FOG LAMP
When a vehicle experiences problems with the
front fog lamp system, verify the condition of the bat-
tery connections, fuses, charging system, fog lamp
bulbs, wire connectors, relay, high beam switch, and
headlamp switch. Refer to the appropriate wiring
information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
FRONT FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.1. Loose or corroded battery
cables.1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of-charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical, Battery
System.
6. Poor lighting circuit Z349/Z248
ground.6. Test for voltage drop across Z349/248
ground locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS
BURN OUT
FREQUENTLY1. Charging system output too
high.1. Test and repair charging system. Refer to
Electrical, Charging.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
FOG LAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer to
Electrical, Charging.
2. Poor lighting circuit Z349/Z248
ground.2. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp circuit.
Fig. 7 CHMSL ELECTRICAL CONNECTOR
1 - CHMSL UNIT
2 - CHMSL ELECTRICAL CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-7
CENTER HIGH MOUNTED STOP LAMP UNIT (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS FLASH
RANDOMLY1. Poor lighting circuit Z349/Z248
ground.1. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
2. Variable resistance in fog lamp
circuit.2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.
6. PCI Bus Communication. 6. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
Information.
2. No Z349/Z248 ground at fog
lamps.2. Repair circuit ground. Refer to Electrical,
Wiring Information.
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Broken connector terminal or
wire splice in fog lamp circuit.4. Repair connector terminal or wire splice.
5. Faulty or burned out bulb. 5. Replace bulb.
6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.
7. PCI Bus Communication. 7. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind the bumper fascia, twist bulb
counter-clockwise, and remove bulb. (Fig. 8).
(3) Remove the wire connector from the fog lamp
bulb.
INSTALLATION
(1) Reconnect wire harness to bulb.
(2) Install bulb and twist clockwise.
(3) Install battery negative cable.
Fig. 8 FRONT FOG LAMP
1 - FRONT FOG LAMP MOUNTING NUT
2 - FRONT FOG LAMP
8L - 8 LAMPS/LIGHTING - EXTERIORRS
FRONT FOG LAMP (Continued)

HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.1. Loose or corroded battery
cables.1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.1. Integrated Power Module (IPM)
not controlling voltage.1. Test and repair Integrated Power Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
HEADLAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE.1. Charging system output too low. 1. Test and repair charging system, refer to
Electrical, Wiring Information.
2. Poor lighting circuit Z343/Z344-
ground.2. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z343/Z344-
ground.1. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
2. Variable resistance in headlamp
circuit.2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or
splices in circuit.3. Inspect and repair all connectors and splices,
refer to Electrical, Wiring Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
RSLAMPS/LIGHTING - EXTERIOR8L-11
HEADLAMP (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS DO NOT
ILLUMINATE.1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No Z343/Z344-ground at
headlamps.2. Repair circuit ground, refer to Electrical,
Wiring Information.
3. Broken connector terminal or
wire splice in headlamp circuit.3. Repair connector terminal or wire splice.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module
malfunction.5. Refer to appropriate Body Control Module
diagnostics.
6. PCI Bus Communication 6. Verify messages being transmitted by BCM
and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM diagnostics.
HEADLAMPS ON WITH
IGNITION IN RUN, WITH
HEADLAMP SWITCH
OFF.1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
logged faults).
2. Diagnostic tool indicates (4.7 -
5.0V) on headlamp switch input to
BCM.2. Inspect and repair terminals, connectors and
open circuits.
3. PCI Bus Communication. 3. Verify messages being transmitted by BCM
and received by FCM.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit retaining screws.
(3) Remove headlamp unit to expose back of unit.
(4) Remove wiring connector from bulb.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.(6) Pull headlamp bulb and remove from headlamp
unit (Fig. 11).
INSTALLATION
(1) Install headlamp bulb to the headlamp unit.
(2) Install headlamp bulb retaining ring.
(3) Connect wiring connector to bulb.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Reconnect the battery negative cable.
HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH
Using a Digital Multi-meter, perform the HEAD-
LAMP SWITCH CONTINUITY test and refer to (Fig.
12).
If the Headlamp Switch is not within specifications
replace the switch.
Fig. 11 HEADLAMP
1 - HEADLAMP
2 - HEADLAMP UNIT
8L - 12 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP (Continued)

also affect compass operation. If the vehicle roof
should become magnetized, the demagnetizing and
calibration procedures found in this section may be
required to restore proper compass operation.
DESCRIPTION - TEMPERATURE
All the available overhead consoles on this model
include Temperature information. The temperature
displays the outside ambient temperature in whole
degrees. The temperature display can be toggled
from Fahrenheit to Celsius by selecting the desired
U.S./Metric option from the customer programmable
features. The displayed temperature is not an instant
reading of conditions, but an average temperature. It
may take the temperature display several minutes to
respond to a major temperature change, such as driv-
ing out of a heated garage into winter temperatures.
When the ignition switch is turned to the Off posi-
tion, the last displayed temperature reading stays in
the electronic control modules (CT, CMTC, EVIC)
memory. When the ignition switch is turned to the
On position again, the electronic module will display
the memory temperature for one minute; then update
the display to the current average temperature read-
ing within five minutes.
The temperature function is supported by an ambi-
ent temperature sensor. The sensor is mounted out-
side the passenger compartment near the front and
center of the vehicle, and is hard wired to the Front
Control Module (FCM). The FCM sends temperature
status messages to the module over the J1850 PCI
data bus circuit.
Following are general descriptions of the major
components used in the overhead console. Refer to
Wiring Diagrams for complete circuit schematics.
OPERATION
Refer to the vehicle Owner's Manual for specific
operation of each overhead console and its systems.
DIAGNOSIS AND TESTING - OVERHEAD
CONSOLE
If the problem with the overhead console is an
inaccurate or scrambled display, refer toSelf-Diag-
nostic Testbelow. If the problem with the overhead
console is incorrect Vacuum Fluorescent Display
(VFD) dimming levels, use a DRB IIItscan tool and
the proper Diagnostic Procedures manual to test for
the correct dimming message inputs being received
from the Body Control Module (BCM) or Front Con-
trol Module (FCM) over the J1850 Programmable
Communications Interface (PCI) data bus circuit. If
the problem is a no-display condition, use the follow-
ing procedures. For complete circuit diagrams, refer
toOverhead Consolein the Wiring Diagrams sec-
tion of the service manual.(1) Check the fused B(+) fuse in the integrated
power module. If OK, go to Step 2. If not OK, repair
the shorted circuit or component as required and
replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the integrated power module. If OK, go to Step 3.
If not OK, repair the open fused B(+) circuit to the
fused B(+) fuse in the integrated power module as
required.
(3) Check the fused ignition switch output (run/
start) fuse in the integrated power module. If OK, go
to Step 4. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse.
(4) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/start) fuse in the integrated power mod-
ule. If OK, go to Step 5. If not OK, repair the open
fused ignition switch output (run/start) circuit to the
ignition switch as required.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the overhead console. Check for continuity
between the ground circuit cavity of the roof wire
harness connector for the electronics module and a
good ground. There should be continuity. If OK, go to
Step 6. If not OK, repair the open ground circuit to
ground as required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
roof wire harness connector for the electronics mod-
ule. If OK, go to Step 7. If not OK, repair the open
fused B(+) circuit to the fused B(+) fuse in the inte-
grated power module as required.
(7)
Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/start) circuit cavity of the roof wire har-
ness connector for the electronics module. If OK, refer
toSelf-Diagnostic Test
later this group for further
diagnosis of the electronics module and the J1850
PCI data bus circuit. If not OK, repair the open fused
ignition switch output (run/start) circuit to the fuse
in the integrated power module as required.
SELF-DIAGNOSTIC TEST
A self-diagnostic test is used to determine that the
electronics module is operating properly, and that all
the J1850 PCI data bus messages are being received
for initial operation. Initiate the self-diagnostic test
as follows:
(1) With the ignition switch in the Off position, on
Electronic Vehicle Information Center (EVIC) and
Compass Mini-Trip Computer (CMTC) equipped vehi-
cles simultaneously depress and hold theSTEP and
the RESET buttons. On Compass Temperature
Module (CT) equipped vehicles depress theC/T and
the US/M push buttons.
8M - 2 MESSAGE SYSTEMSRS
OVERHEAD CONSOLE (Continued)

CAUTION: Do not disconnect the switch from the
rear of the door key cylinder. This switch is a one
time use switch. Once it is removed from the rear of
the switch, it is not reusable and must be replaced.
Test the switch at the harness connector.
DOOR CYLINDER LOCK SWITCH RESISTANCE
SWITCH POSITION RESISTANCE VALUE
COUNTERCLOCKWISE 5.4K OHMS
NEUTRAL 18.4K OHMS
CLOCKWISE 2K OHMS
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel of the effected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - REMOVAL).
(3) Close the door window.
(4) Disconnect the door cylinder lock switch wire
connector from the door harness, and wiring clip
from the impact beam.
(5) Remove the outer door handle from the door.
(6) Remove the switch from the key cylinder in the
door handle and remove from vehicle.
INSTALLATION
(1) Install the switch on the key cylinder in the
door handle.
(2) Install the door handle.
(3) Connect the door cylinder lock switch wire con-
nector to the door harness, and the wiring clip to the
impact beam.
(4) Install the door trim panel of the affected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Verify system operation.
DOOR LOCK MOTOR
DIAGNOSIS AND TESTING - DOOR LOCK
MOTOR
Verify battery condition before testing door lock
motor(s) (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - DIAGNOSIS AND TESTING).
To determine which motor is faulty, check each
individual door for electrical lock and unlock or dis-
connect the motor connectors one at a time, while
operating the door lock switch. In the event that
none of the motors work, the problem may be caused
by a shorted motor or a bad switch. Disconnecting
the defective motor will allow the others to work.To test an individual door lock motor, disconnect
the electrical connector from the motor. To lock the
door, connect a 12 volt power source to the positive
pin of the lock motor and a ground wire to the other
pin. 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 har-
ness connectors, splices and grounds. To unlock the
door reverse the wire connections at the motor pin
terminals. If these results are NOT obtained, replace
the motor.
DOOR LOCK SWITCH
DIAGNOSIS AND TESTING - DOOR LOCK
SWITCH
(1) Remove door trim panel. Refer to Body, Door -
Front, Trim Panel, Removal and Installation.
(2) Disconnect wire connector from back of door
lock switch.
(3) Depress switch to LOCK position.
(4) Using an ohmmeter, test switch resistance
between Pins 2 and 3. Refer to the DOOR LOCK
SWITCH CONTINUITY test and (Fig. 2).
(5) Depress switch to UNLOCK position.
(6) Test resistance between Pins 2 and 3.
(7) Test resistance between pins 2 and 3 while
switch is in its normal unactuated mode.
(8) If resistance values are not within the param-
eters shown replace the door lock switch.
DOOR LOCK SWITCH CONTINUITY
SWITCH
POSITIONCONTINUITY
BETWEENRESISTANCE
VALUE
LOCK 2 and 3 5.3K Ohm   5%
UNLOCK 2 and 3 2.0K Ohm   5%
UNACTUATED 2 and 3 18.3K Ohms  
5%
Fig. 2 DOOR LOCK SWITCH
RSPOWER LOCKS8N-41
DOOR CYLINDER LOCK SWITCH (Continued)

(2) Turn the ignition key to the ON position. Exit
vehicle with the scan tool.
(3) After checking that no one is inside the vehicle,
connect the battery negative remote terminal.
(4) Read and record theACTIVEDiagnostic Trou-
ble Code (DTC) data.
(5) Read and record anySTOREDDTC's.
(6) Refer to the proper Body Diagnostic Procedures
manual if any DTC's are found in Step 4 and Step 5.
(7) If the airbag warning lamp either fails to light,
or goes ON and stays ON, there is a system malfunc-
tion. To test the airbag warning lamp (bulb) opera-
tion in the cluster, refer to Electrical, Instrument
Cluster, Diagnosis and Testing - Instrument Cluster.
Refer to the proper Body Diagnostic Procedures man-
ual for any other system problems.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
AIRBAGS
DEPLOYED AIRBAG
The vehicle interior may contain a very small
amount of sodium hydroxide powder, a by-product of
airbag deployment. Sodium hydroxide powder can
irritate the skin, eyes, nose and throat. Wear safety
glasses, rubber gloves, and long sleeved clothing
when cleaning any of the powder residue from the
vehicle.
If you find that the cleanup is irritating your skin,
run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle
for fresh air until the irritation ceases. If irritation
continues, see a physician.
UNDEPLOYED AIRBAG
The airbags must be stored in its original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag module. When carrying or han-
dling an undeployed airbag module, the trim side of
the airbag should be pointing away from the body to
minimize possibility of injury if accidental deploy-
ment occurs. Do not place undeployed airbag face
down on a solid surface, the airbag will propel into
the air if accidental deployment occurs.
STANDARD PROCEDURE - SERVICE AFTER AN
AIRBAG DEPLOYMENT
DRIVER AIRBAG
After a Driver Airbag has been deployed due to a
collision, the followingMUSTbe replaced:
²Driver Airbag²Clock Spring Assembly
²Steering Wheel
²Complete Steering Column Assembly w/Lower
Steering Column Coupler
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
PASSENGER AIRBAG
After a Passenger Airbag has been deployed due to
a collision. the followingMUSTbe replaced:
²Passenger Airbag
²Instrument Panel and Pad Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT AIRBAG
After a Seat Airbag has been deployed due to a col-
lision. the followingMUSTbe replaced:
²Complete Seat Back Assembly
All other airbag and vehicle components should be
closely inspected following any airbag deployment,
and should be replaced when visible damage is
incurred.
SEAT BELTS AND TENSIONERS
After a frontal impact where an airbag has been
deployed due to a collision. the followingMUSTbe
replaced:
²Front Seat Belt Buckle (driver and passenger)
with integral Tensioners.
All other seat belts should be closely inspected for
cuts, tears, fraying, or damage in any way following
any frontal impact or airbag deployment. The other
seat belts are to be replaced when visible damage is
incurred. Inspect the Lower Anchors and Tether for
CHildren (LATCH) child restraint anchors for dam-
age after an impact event and replace as needed.
CLEAN UP PROCEDURE
Roll or fold the airbag towards its mounting point
(i.e. instrument panel, steering wheel, or seat back).
Then tape the ripped cover over the deployed airbag
if applicable.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well (Fig.
1). If the heater or air conditioner was in RECIRC
mode at time of airbag deployment, operate blower
motor on low speed and vacuum powder residue
expelled from the heater and A/C outlets. Multiple
RSRESTRAINTS8O-3
RESTRAINTS (Continued)

SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION..........................1
OPERATION
OPERATION..........................1
OPERATION - INTERACTIVE SPEED
CONTROL (4 Speed EATX Only)...........2
DIAGNOSIS AND TESTING - ROAD TEST.....3
SPECIFICATIONS - TORQUE...............3
CABLE
DESCRIPTION..........................4
OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
SERVO
DESCRIPTION..........................4OPERATION............................4
REMOVAL.............................5
INSTALLATION..........................5
SWITCH
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................6
VACUUM RESERVOIR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................6
SPEED CONTROL
DESCRIPTION
The speed control system is electronically con-
trolled and vacuum operated. The electronic control
is integrated into the Powertrain Control Module.
The controls are located on the steering wheel. The
ON/OFF, and SET buttons are located on the left side
of the airbag module. The RESUME/ACCEL, CAN-
CEL and COAST buttons are located on the right
side of the airbag module (Fig. 1).The system is designed to operate at speeds above
30 mph (48 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
OPERATION
When speed control is activated by depressing the
ON switch, the PCM allows a set speed to be stored
in RAM for speed control. To store a set speed,
depress and release the SET switch while the vehicle
is moving at a speed between 30 and 85 mph. In
order for the speed control to engage, the brakes can-
not be applied, nor can the gear selector be indicat-
ing the transmission is in Park or Neutral (ATX) or
1st/2nd gear (MTX). The speed control can be disen-
gaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
²Depressing the clutch pedal
²Operating in 1st or 2nd gear (autostick, if
equipped)
Fig. 1 SPEED CONTROL SWITCHES - Typical
RSSPEED CONTROL8P-1