2004 CHRYSLER VOYAGER light

CHIME/THERMISTOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
chime/thermistor assembly. The chime/thermistor
assembly is a small capacitor shaped electrical com-
ponent mounted to the rear license plate lamp hous-
ing assembly (Fig. 4) , located just above the license
plate. The chime portion of the assembly controls the
audible chime sound heard at the rear of the vehicle
when the power liftgate is in motion. The thermistor
portion of the assembly is a temperature sensor, used
by the power liftgate module.
The chime/thermistor assembly is a serviceable
component. Consult your MoparŸ parts catalog for a
specific part number.
OPERATION
The chime/thermistor assembly performs two dif-
ferent functions for the power liftgate system. First,
the chime portion provides an audible chime sound
which is controlled by the power liftgate module. The
chime/thermistor assembly is hardwired to the power
liftgate module. Second the thermistor provides a
outside temperature reading by way of a resistance
reading (V- ohms) supplied to the power liftgate
module. As temperature increases the resistance
reading (V- ohms) increases, as temperature
decreases the resistance reading (V- ohms)
decreases.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the rear light bar assembly from the
vehicle. Refer to Body for the procedure.
(3) Using your hands, grasp the light bar at its
sides next to thermistor/chime assembly and gently
pull the two sides of the light bar apart until the
thermistor/chime assembly can be removed.
INSTALLATION
(1) Gently pull the two sides of the light bar apart
until the thermistor/chime assembly can be installed.
(2) Install the rear light bar assembly on the vehi-
cle. Refer to the Body section of the service manual
for the procedure.
(3) Connect the negative battery cable.
ENGAGE ACTUATOR
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
power liftgate engage actuator (Fig. 5). 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.
Fig. 4 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 5 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
8N - 10 POWER LIFTGATE SYSTEMRS

(3) Remove the rear lamp bar assembly from the
vehicle. Refer to the Body section of the service man-
ual for the procedure.
(4) Locate the two wires going to the exterior han-
dle switch. Cut the tie strap and trace the wires to
the large electrical connector and back the wires out
of the large connector and through the grommet.
Refer to the Wiring section of the service manual for
detailed instructions.
(5) Depress the two exterior handle switch retain-
ing tabs and roll the switch out of the light bar
assembly (Fig. 7).
INSTALLATION
(1) Install the handle switch in the light bar
assembly.
(2) Locate the two wires going to the exterior han-
dle switch. Install the wires through the grommet
and in the large connector. Secure with a tie strap.
Refer to the Wiring section of the service manual for
detailed instructions.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the handle switch. Refer to Wiring Diagrams
if previous notes were not made.
(3) Install the rear light bar. Refer to the Body sec-
tion of the service manual for the procedure.
(4) Install the liftgate trim panel. Refer to the
Body section of the service manual 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.
(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate through one com-
plete open and close cycle, this will allow the power
liftgate control module to relearn its cycle with the
new components.
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. 8) 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-
Fig. 7 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 8 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
8N - 12 POWER LIFTGATE SYSTEMRS
EXTERIOR HANDLE SWITCH (Continued)

REMOVAL
(1) Disconnect and isolate the negative cable.
(2) Remove the side door trim panel from the vehi-
cle. Refer to the Body section for the procedure.
(3) Remove the weathershield. Refer to the Body
section for the procedure.
(4) Remove the E-clip from the flex drive assembly
(Fig. 19).
(5) Pull the flex drive straight out of the motor
assembly.
(6) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 20).
(7) Expand the flex drive collar, next to the lower
drive unit until the flex drive can be pulled straight
off the lower drive unit.
(8)
Remove the flex drive assembly from the vehicle.
INSTALLATION
(1) Position the flex drive assembly in the vehicle.
(2) Install the flex drive on the lower drive unit.
Push straight on until it snaps in place. It may be
necessary to rotate drive unit gear slightly until the
flex drive seats in place.
(3) Install the lower drive unit cover and retaining
screws.
(4) Install the flex drive in the motor assembly.
Line up the square shaped inner shaft and push
straight on (Fig. 21).
(5) Install the E-clip on the flex drive assembly
(Fig. 19).(6) Install the weathershield. Refer to Body for the
procedure.
(7) Install the side door trim panel on the vehicle.
Refer to Body for the procedure.
(8) Connect the negative cable.
Fig. 19 Flex Drive E-Clip
1 - Flex Drive Cable Retaining Clip
2 - Flex Drive Cable
3 - Side Door Motor Assembly
Fig. 20 Lower Hinge/Drive Assembly
1 - Lower Drive Unit Cover
2 - Lower Drive Unit Cover Retaining Screws
3 - Sliding Door
4 - Lower Hinge Arm Bracket
Fig. 21 Flex Drive Cable
1 - Door Motor
2 - Flex Drive Collar
3 - Flex Drive Inner Shaft
RSPOWER SLIDING DOOR SYSTEM8N-37
FLEX DRIVE (Continued)

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove door trim panel. Refer to Body, Door -
Front, Trim Panel, Removal.
(3) Disconnect wire connector from back of door
lock switch.
(4) Remove two screws to door lock switch.
(5) Remove switch from vehicle.
INSTALLATION
(1) Install the switch into the vehicle.
(2) Install the two screws to door lock switch.
(3) Connect wire connector to back of door lock
switch.
(4) Install door trim panel. Refer to Body, Door -
Front, Trim Panel, Installation.
(5) Connect the battery negative cable.
KEYLESS ENTRY
TRANSMITTER
DIAGNOSIS AND TESTING - KEYLESS ENTRY
TRANSMITTER
Using special tool 9001, first test to ensure that
the transmitter is functioning. Typical testing dis-
tance is 2.5 centimeters (1 inch) for Asian transmit-
ters and 30.5 centimeters (12 inches) for all others.
To test, position the transmitter as shown (Fig. 3).
Press any transmitter button, then test each button
individually. The tool will beep if a radio signal
strength that lights five or more LED's is detected.
Repeat this test three times. If transmitter fails any
of the test, test the batteries. If batteries test OK,
refer to the Diagnostic Procedures manual.
STANDARD PROCEDURE
STANDARD PROCEDURE - HORN CHIRP
PREFERENCE
DISABLING
The horn chirp can be toggled using a DRB IIItor
by using a programmed Remote Keyless Entry (RKE)
transmitter.
To DISABLE (cancelling) the horn chirp feature,
press and hold the transmitter LOCK button for a
minimum of five seconds. While pressing the LOCK
button in, press the UNLOCK button. The horn chirp
feature will not function until the above procedure is
repeated.
ENABLING
The horn chirp can be toggled using a DRB IIItor
by using the Remote Keyless Entry (RKE) transmit-
ter.
To ENABLE (reinstate) the horn chirp feature, use
any one of the four programmed key fob transmitters
and reverse the above procedures. It will ENABLE
the horn chirp feature for all transmitters.
STANDARD PROCEDURE - BATTERY
REPLACEMENT
(1) With the transmitter buttons facing down, use
a coin (a penny is suggested) to pry the two halves of
the transmitter apart (Fig. 4). Make sure not to dam-
age the rubber gasket during separation of the hous-
ing halves.
(2) Remove the battery from the transmitter back
housing holder.
(3) Replace the batteries. Avoid touching the new
batteries with your fingers, Skin oils may cause bat-
tery deterioration. If you touch a battery, clean it off
with rubbing alcohol.
(4) To assemble the transmitter case, snap the two
halves together.
Fig. 3 TRANSMITTER DIAGNOSIS
Fig. 4 RKE TRANSMITTER BATTERY
REPLACEMENT - TYPICAL
1 - INSERT THIN COIN
8N - 42 POWER LOCKSRS
DOOR LOCK SWITCH (Continued)

POWER MIRRORS
TABLE OF CONTENTS
page page
POWER MIRRORS
DESCRIPTION.........................45
OPERATION...........................45
DIAGNOSIS AND TESTING - POWER
MIRRORS...........................46
AUTOMATIC DAY / NIGHT MIRROR
DESCRIPTION.........................47
OPERATION...........................47
DIAGNOSIS AND TESTING - AUTOMATIC DAY
/ NIGHT MIRROR......................47
POWER FOLDAWAY MIRROR SWITCH -
EXPORT
DESCRIPTION.........................48OPERATION...........................48
REMOVAL.............................48
INSTALLATION.........................49
REMOTE SWITCH
DIAGNOSIS AND TESTING - REMOTE
SWITCH............................49
REMOVAL.............................49
INSTALLATION.........................49
SIDEVIEW MIRROR
REMOVAL.............................49
POWER MIRRORS
DESCRIPTION
If equipped with power mirrors, the control switch
is located on the instrument panel to the left of the
headlamp switch.
OPERATION
The power mirrors are connected to battery feed at
all times. Each mirror head contains two electric
motors, two drive mechanisms, an electric heating
element, and the mirror glass. If the vehicle is
equipped with the optional memory system, the
driver side mirror head also contains both a horizon-
tal and a vertical motor position sensor. One motor
and drive controls mirror up-and-down movement,
and the other controls right-and-left movement.An optional driver side outside electrochromic mir-
ror is able to automatically change its reflectance
level. This mirror is controlled by the circuitry of the
automatic day/night inside rear view mirror. A thin
layer of electrochromic material between two pieces
of conductive glass make up the face of the mirror.
Two photocell sensors on the inside rear view mirror
are used to monitor light levels and adjust the reflec-
tance of both the inside and driver side outside mir-
rors. This change in reflectance helps to reduce the
glare of headlamps approaching the vehicle from the
rear. (Refer to 8 - ELECTRICAL/POWER MIRRORS/
AUTOMATIC DAY / NIGHT MIRROR - DESCRIP-
TION) for more information on this system.
The motors which operate the mirrors are part of
the mirror assembly and cannot be serviced sepa-
rately.
RSPOWER MIRRORS8N-45

AUTOMATIC DAY / NIGHT
MIRROR
DESCRIPTION
An automatic dimming inside day/night rear view
mirror and an automatic dimming driver side outside
rear view mirror are available factory-installed
options on this model. Following is a general descrip-
tion of this optional equipment.
The automatic day/night mirror is able to automat-
ically change its reflectance. A thin layer of electro-
chromic material between two pieces of conductive
glass make up the face of the mirror. Two photocell
sensors are used to monitor light levels and adjust
the reflectance of the mirror to reduce the glare of
headlamps approaching the vehicle from the rear.
For removal procedures, (Refer to 23 - BODY/IN-
TERIOR/REAR VIEW MIRROR - REMOVAL).
OPERATION
The ambient photocell sensor faces forward, to
detect the outside light levels. A second sensor faces
rearward to detect the light level received through
the vehicles back window. When the difference
between the two light levels becomes too great (the
light level received at the rear of the mirror is much
higher than that at the front of the mirror), the mir-
ror begins to darken.
The mirror switch allows the driver a manual con-
trol of whether the automatic dimming feature is
operational. When AUTO is selected a small Light-
Emitting Diode (LED), to the right of the mirror
switch, is illuminated. The automatic dimming fea-
ture will only operate when the ignition switch is in
the On position. The mirror also senses the backup
lamp circuit, and will automatically disable its self-
dimming feature whenever the transmission gear
selector is in the Reverse position.
NOTE: The mirror always defaults to an ON state
upon ignition.
The driver side automatic dimming mirror is stan-
dard with the automatic dimming inside mirror. The
signal to control the dimming of that mirror is gen-
erated by the automatic day/night inside rear view
mirror circuitry. That signal is then delivered to the
driver side outside rear view mirror on a hard wired
circuit.
The automatic day/night mirror cannot be
repaired. If faulty or damaged, the entire inside rear
view mirror assembly must be replaced.
DIAGNOSIS AND TESTING - AUTOMATIC DAY /
NIGHT MIRROR
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
(1) Check the fuse in the intelligent power module.
If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fuse in the intelli-
gent power module. If OK, go to Step 3. If not OK,
repair the open circuit to the ignition switch as
required.
(3) Unplug the wire harness connector from the
automatic day/night mirror. Check for battery voltage
at the fused ignition switch output circuit cavity of
the automatic day/night mirror wire harness connec-
tor. If OK, go to Step 4. If not OK, repair the open
circuit to the junction block as required.
(4) Turn the ignition switch to the Off position.
Check for continuity between the ground circuit cav-
ity of the automatic day/night mirror wire harness
connector and a good ground. There should be conti-
nuity. If OK, go to Step 5. If not OK, repair the cir-
cuit to ground as required.
(5) Turn the ignition switch to the On position. Set
the parking brake. Place the transmission gear selec-
tor lever in the Reverse position. Check for battery
voltage at the backup lamp switch output circuit cav-
ity of the automatic day/night mirror wire harness
connector. If voltage is present, reinstall the auto-
matic day/night mirror wire harness connector and
go to Step 6. If not OK, repair the open circuit as
required.
(6) Place the transmission gear selector lever in
the Neutral position. Place the automatic day/night
mirror switch in the On (LED in the switch is
lighted) position. Cover the forward facing ambient
photocell sensor to keep out any ambient light.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7)
Shine a light into the rearward facing headlamp
photocell sensor. The automatic day/night mirror
should darken. The automatic day/night mirror should
darken within 2 minutes if testing for the first time.
For immediate response, turn the vehicle OFF and
back ON with the forward-facing light sensor still cov-
RSPOWER MIRRORS8N-47

ered. This defeats the day-detect logic. If OK, go to
Step 8. If not OK, replace the faulty mirror unit.
(8) With the mirror darkened, place the transmis-
sion gear selector lever in the Reverse position. The
automatic day/night mirror should return to its nor-
mal reflectance. If not OK, replace the faulty mirror
unit.
Bench testing both mirrors can be done, of care is
exercised. For an inside mirror, the pin closest to he
mount is 12V (+), the next is 12V (-). The third is
reverse override. The fourth is outside mirror (+),
and the fifth is outside mirror (-).Do not apply 12
volts to the fourth and fifth pins.With 12 volts
on pins 1 and 2, the mirror can be tested by blocking
the rear sensor and shining a light into the forward
sensor. For an outside mirror, there is a 2±pin con-
nector. Applying 1.2 volts will cause the mirror to
dim. If the mirror does not dim, the entire glass
assembly can be replaced just as it is when the glass
is broken.
WARNING: Do not apply 12 volts to the outside mir-
ror. Damage to the mirror will result.
POWER FOLDAWAY MIRROR
SWITCH - EXPORT
DESCRIPTION
These vehicles may be equipped with Power Fold-
away Mirrors. This feature allows both the driver
and passenger side view mirrors to fold inward
(retract) on demand. The vehicle has an additional
switch located on the steering column that controls
the folding function of the mirror assembly (Fig. 2).
The fold-away side view mirror is attached to the
vehicle's door in the same manner as mirrors without
the fold-away option. The fold-away mirrors unique
option is the internal motor which allows the mirrors
to fold inward on demand. The fold-away mirror
motor is not serviceable separately and if a motor is
found to be faulty the entire side view mirror must
be replaced.
OPERATION
When the mirror retract switch is depressed, both
of the side view mirrors will fold inward, Thus mak-
ing the overall width of the vehicle the smallest pos-
sible. This can be helpful were parking space is a
absolute minimum.
When the driver's door is opened, only the driver's
door mirror will unfold. If the passenger door is
opened, both mirrors will unfold.
The power fold away mirror system consists of the
following components: mirror switch, side view mir-ror, relay, wires and fuse. Refer to the appropriate
wiring information. The wiring information includes
wiring diagrams, proper wire and connector repair
procedures, details of wire harness routing and
retention, connector pin-out information and location
views for the various wire harness connectors, splices
and grounds.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the upper and lower steering column
shroud (Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(3) Disconnect electrical harness connector.
(4) Remove switch from steering column shroud
(Fig. 3).
Fig. 2 POWER FOLDAWAY MIRROR SWITCH
1 - POWER FOLDAWAY MIRROR SWITCH
2 - STEERING COLUMN
Fig. 3 POWER FOLDING MIRROR SWITCH
1 - STEERING COLUMN SHROUD
2 - POWER FOLDAWAY SWITCH
8N - 48 POWER MIRRORSRS
AUTOMATIC DAY / NIGHT MIRROR (Continued)

TESTING POWER SEAT TRACK MOTORS
(1) Check the power seat circuit breaker under the
seat. If OK, go to Step 2. If not OK, replace the
faulty power seat circuit breaker.
(2) Check for battery voltage at the power seat cir-
cuit breaker under the seat. If OK, go to Step 3. If
not OK, repair the open fused B(+) circuit to the fuse
in the Intelligent Power Module as required.
(3) Remove the outboard seat cushion side shield
from the seat. Disconnect the seat wire harness con-
nector from the power seat switch connector recepta-
cle. Check for battery voltage at the fused B(+)
circuit cavity of the power seat wire harness connec-
tor for the power seat switch. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the
power seat circuit breaker under the seat as
required.
(4) Check for continuity between the ground cir-
cuit cavity of the power seat wire harness connector
for the power seat switch and a good ground. There
should be continuity. If OK, go to Step 5. If not OK,
repair the open ground circuit to ground as required.
(5) Test the power seat switch. Refer toDiagnosis
and Testing Power Seat Switchin this section. If
the switch tests OK, test the circuits of the power
seat wire harness between the inoperative power seat
track adjuster motor and the power seat switch for
shorts or opens. If the circuits check OK, replace the
faulty power seat track unit. If the circuits are not
OK, repair the power seat wire harness as required.
REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the appropriate seat from the vehicle
and place it on a clean work surface(Refer to 23 -
BODY/SEATS/SEAT - REMOVAL).
(2) If the vehicle is so equipped, remove the Mem-
ory Seat/Mirror Module (MSMM) retaining screws.
(3) If the vehicle is so equipped, disconnect the
MSMM electrical connectors and remove the MSMM
from the power seat track.
(4) Remove the rear fabric blocker trim panel from
the rear of the front seat.(5) Remove the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - REMOVAL).
(6) Disconnect all electrical connectors connecting
the power seat track to the seat assembly.
(7) Pull the seat back trim cover up slightly to
access and remove the two seat back frame mounting
bolts and also remove two seat back recliner bolts.
(8) Remove four seat track mounting bolts from
the seat cushion pan.
(9) Remove the power seat track from the seat.
INSTALLATION
(1) Position the seat cushion on the seat track.
(2) Install the four seat track retaining bolts in the
seat cushion pan. Torque the bolts to 28.5 N´m.
(3) Position the seat back and install the two seat
back frame mounting bolts and the two seat back
recliner bolts. Torque the bolts to 55 N´m.
(4) Route and connect the electrical connectors
between the power seat track and the seat assembly.
(5) Install the seat side cover and power seat
switch as an assembly (Refer to 23 - BODY/SEATS/
SEAT CUSHION SIDE COVERS - INSTALLATION).
(6) Install the rear fabric blocker trim panel on the
rear of the front seat.
(7) If the vehicle is so equipped, position the Mem-
ory Seat/Mirror Module (MSMM) and connect the
MSMM electrical connectors.
(8) Install the MSMM retaining screws.
(9) Install the seat assembly in the vehicle (Refer
to 23 - BODY/SEATS/SEAT - INSTALLATION).
PASSENGER POWER SEAT
TRACK
DESCRIPTION
The four-way passenger side power seat option
includes a electrically operated power seat track unit
located under the passenger side front seat. The
power seat circuit breaker is mounted on the rear of
the power seat track, just behind the seat rear trim
panel. The lower half of the power seat track is
secured to the floor panel via four studs and nuts
that must be accessed from the underside of the vehi-
cle. Four bolts secure the bottom of the seat cushion
frame to the upper half of the power seat track unit.
Four additional bolts secure the seat back frame to
the power seat track unit.
The passenger side power seat track unit includes
two reversible electric motors that are secured to the
upper half of the track unit. Each motor moves the
seat adjuster through a combination of worm-drive
gearboxes and screw-type drive units. The horizontal
adjustment motor moves the seat track in the for-
RSPOWER SEAT SYSTEM8N-59
DRIVER POWER SEAT TRACK (Continued)