2004 CHRYSLER VOYAGER ECU

INSTALLATION
(1) Snap the left side of the Integrated Power Mod-
ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors. Care must be
taken that the Connector Positive Assurance (CPA)
on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).
NOTE: IPM electrical connectors are color coded to
ease location reference.
(2) Being certain no wires are stressed or pinched,
rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.
(3) Install the battery in the vehicle. Refer to the
Battery section for the procedure.
(4) Install the battery thermal guard in the vehi-
cle. Refer to the Battery section for the procedure.
(5)
Connect the negative and positive battery cables.
(6) Using a diagnostic scan tool, check for any
stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) whenthe vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.
The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
tion. The IOD fuse is a 20 ampere blade-type mini
fuse and, when removed, it is stored in a fuse cavity
adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal condi-
tion where power is being drained from the battery with
the ignition switch in the Off position. The IOD fuse
feeds the memory and sleep mode functions for some of
the electronic modules in the vehicle as well as various
other accessories that require battery current when the
ignition switch is in the Off position, including the
clock. The only reason the IOD fuse is removed is to
reduce the normal IOD of the vehicle electrical system
during new vehicle transportation and pre-delivery stor-
age to reduce battery depletion, while still allowing
vehicle operation so that the vehicle can be loaded,
unloaded and moved as needed by both vehicle trans-
portation company and dealer personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
Fig. 3 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-3
INTEGRATED POWER MODULE (Continued)

POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). 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 IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3) Open the power outlet door. Check for continu-
ity between the inside circumference of the power
outlet receptacle and a good ground. There should be
continuity. If OK, go to Step 4. If not OK, go to Step
5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector 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
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS

(41) Disconnect the knock sensor electrical connec-
tor (3.8L only).
(42) Disconnect the engine block heater electrical
connector (if equipped).
(43) Remove the accessory belt splash shield.
(44) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(45) Disconnect the radiator lower hose.
(46) Remove air conditioning compressor from
engine.
(47) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(48)
Remove the water pump pulley attaching bolts
and position pulley between pump hub and housing.
(49) Disconnect the oil pressure switch electrical
connector.
(50) Disconnect wiring harness support clip from
engine oil dipstick tube.
(51) Install Special Tools 6912 and 8444 Adapters
on the right side (rear) of engine block (Fig. 9).
(52) Lower the vehicle.
(53) Remove the power steering pump and set
aside.
(54) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 withpost Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 12).
(55) Loosen cradle/post mounts to allow movement
for positioning posts into locating holes on the engine
(Fig. 10) and (Fig. 11). Slowly lower vehicle and posi-
tion cradle/post mounts until the engine is resting on
posts. Tighten all cradle/post mounts to cradle frame.
This will keep mounts from moving when removing
or installing engine and transmission.
(56) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(57) Install and secure the safety straps to the cra-
dle fixture and around the engine (Fig. 12).
(58) Remove the engine right side mount to engine
attaching bolts (Fig. 13).
(59) Remove the left mount through bolt (Fig. 14).
(60) Raise vehicle slowly. It is necessary to move
the engine/transmission assembly with the dolly to
allow for removal around body flanges.
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK
1 - SPECIAL TOOL 6912
2 - SPECIAL TOOL 8444
Fig. 10 Positioning Special Tool 6848 for use with
Adapters 8444 & 6912
1 - SLOTS
2 - SPECIAL TOOLS 6848
9 - 88 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
45) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 45). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
HYDRAULIC LIFTERS (CAM IN
BLOCK)
DESCRIPTION
The hydraulic lifters are a roller type design and
are positioned in the cylinder block. The lifters are
aligned and retained by a yoke and a retainer (Fig.
47).Lifter alignment is maintained by machined flats
on lifter body. Lifters are fitted in pairs into six
aligning yokes. The aligning yokes are secured by a
yoke retainer (Fig. 47).
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS
HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY
STEP
Before disassembling any part of the engine to cor-
rect lifter noise, check the engine oil pressure. (Refer
to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND
TESTING)
Check engine oil level. The oil level in the pan
should never be above the MAX mark on dipstick, or
below the MIN mark. Either of these two conditions
could cause noisy lifters.
OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dipstick, it is
possible for the connecting rods to dip into the oil
while engine is running and create foaming. Foam in
oil pan would be fed to the hydraulic lifters by the oil
pump causing them to become soft and allow valves
to seat noisily.
OIL LEVEL TOO LOW
Low oil level may allow pump to take in air which
when fed to the lifters it causes them to become soft
and allows valves to seat noisily. Any leaks on intake
side of pump, through which air can be drawn, will
create the same lifter noise. Check the lubrication
system from the intake strainer to the oil pump
cover, including the relief valve retainer cap. When
lifter noise is due to aeration, it may be intermittent
or constant, and usually more than one lifter will be
noisy. When oil level and leaks have been corrected,
the engine should be operated at fast idle to allow all
of the air inside of the lifters to be bled out.
VALVE TRAIN NOISE
To determine source of valve train noise, operate
engine at idle with cylinder head covers removed and
listen for source of the noise.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy lifters. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
Fig. 45 Checking Cylinder Bore Size
RSENGINE 3.3/3.8L9 - 113
ENGINE BLOCK (Continued)

SPECIAL TOOLS
EXHAUST SYSTEM
CATALYTIC CONVERTER
DESCRIPTION
The toe board three-way catalytic converter is con-
nected to the exhaust manifold by the use of flex
joint and a gasket. The outlet connects to the muffler
inlet pipe and is secured with a band type clamp
(Fig. 1).
The exhaust flex-joint coupling (Fig. 3) is used to
secure the catalytic converter to the exhaust manifold.
The flex-joint has four bolts, four flag nuts and a gas-
ket that are separate parts from the exhaust flex-joint.
The flex-joint is welded to the catalytic converter.
CAUTION: When servicing, care must be exercised
not to dent or bend the bellows or bellows cover of
the flex-joint. Should this occur, the flex-joint will
eventually fail and require the catalytic converter be
replaced.
OPERATION
The three-way catalytic converter simultaneously
converts three exhaust emissions into harmless
gases. Specifically, HC and CO emissions are con-
verted into water (H2O) and carbon dioxide (CO2).
Oxides of Nitrogen (NOx) are converted into elemen-
tal Nitrogen (N) and water. The three-way catalyst is
most efficient in converting HC, CO and NOx at the
stoichiometric air fuel ratio of 14.7:1.
The oxygen content in a catalyst is important for
efficient conversion of exhaust gases. When a high
oxygen content (lean) air/fuel ratio is present for an
extended period, oxygen content in a catalyst can
reach a maximum. When a rich air/fuel ratio is
present for an extended period, the oxygen content in
the catalyst can become totally depleted. When this
occurs, the catalyst fails to convert the gases. This is
known as catalyst9punch through.9
Catalyst operation is dependent on its ability to
store and release the oxygen needed to complete the
emissions-reducing chemical reactions. As a catalyst
deteriorates, its ability to store oxygen is reduced.
Since the catalyst's ability to store oxygen is some-
what related to proper operation, oxygen storage can
be used as an indicator of catalyst performance.
Refer to the appropriate Diagnostic Information for
diagnosis of a catalyst related Diagnostic Trouble
Code (DTC).
Back Pressure Test Adapter - CH8519
Pressure Transducer CH7063
DRB III & PEP Module - OT-CH6010A
Fig. 3 Flex-joint
1 - FLANGE
2 - END CAPS
3 - CATALYTIC CONVERTER
4 - FLEXIBLE BELLOWS
11 - 4 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)

nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, use new original equipment
lines/tubes/hoses.
If equipped:The hose clamps used to secure rub-
ber hoses on vehicles are of a special rolled edge con-
struction. This construction is used to prevent the
edge of the clamp from cutting into the hose. Only
these rolled edge type clamps may be used in this
system. All other types of clamps may cut into the
hoses and cause leaks.
Use new original equipment type hose clamps.
STANDARD PROCEDURE - HOSES AND CLAMP
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (9 in. lbs.) torque.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
FUEL PRESSURE REGULATOR
OPERATION
The fuel system uses a nonadjustable pressure reg-
ulator that maintains fuel system pressure at
approximately 400  34 kPa (58  5 psi). The fuel
pressure regulator contains a diaphragm, calibrated
spring and a fuel return valve. The spring pushes
down on the diaphragm and closes off the fuel returnport. System fuel pressure reflects the amount of fuel
pressure required to open the return port.
The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
REMOVAL
The fuel pressure regulator is part of the fuel
pump module (Fig. 8). Remove the fuel pump module
from the fuel tank to access the fuel pressure regula-
tor. Refer to the Fuel Pump Module removal in this
section.
(1) Squeeze tangs on pressure regulator retainer
and pull to remove retainer.
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
The fuel pressure regulator is part of the fuel
pump module. Remove the fuel pump module from
the fuel tank to access the fuel pressure regulator.
Refer to the Fuel Pump Module removal in this sec-
tion.
(1) Lightly lubricate the O-rings with clean engine
oil and place them into opening in pump module (Fig.
8).
(2) Push regulator into opening in pump module.
(3) Retaining tabs snap into housing.
Fig. 8 Fuel Pressure Regulator O-rings
1 - UPPER O-RING
2 - LOWER 0-RING
RSFUEL DELIVERY14-7
FUEL LINES (Continued)

QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
(1) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(2) Disconnect negative cable from battery or aux-
iliary jumper terminal.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Make sure that the o-ring in installed in
fitting. Never install a quick-connect fitting without
the retainer being either on the fuel tube or already
in the quick-connect fitting. In either case, ensure
the retainer locks securely into the quick-connect
fitting by firmly push-pulling-push on fuel tube and
fitting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean engine oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 22).Do not rely upon the
audible click to confirm a secure connection.
(5) Connect negative cable to battery or auxiliary
jumper terminal.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for several minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.(6) Use the DRB IIItscan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on
both sides of the fitting (Fig. 23). These tabs are sup-
plied for disconnecting the quick-connect fitting from
component being serviced.
CAUTION: The interior components (O-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
Fig. 22 Plastic Quick-Connect Fitting/Fuel Tube
Connection
1 - WINDOW
2-TAB(2)
3 - EAR
4 - SHOULDER (ON TUBE)
Fig. 23 Typical Two-Tab Type Quick-Connect Fitting
1 - TAB(S)
2 - QUICK-CONNECT FITTING
14 - 14 FUEL DELIVERYRS

LOCK CYLINDER HOUSING
DESCRIPTION - IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Unlock, Run or Start position. In
addition, the operator cannot rotate the key to the
lock position unless the shifter is in the park posi-
tion. On vehicles equipped with floor shift refer to
the - Transaxle for Automatic Transmission Shifter/
Ignition Interlock.
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Remove battery ground cable terminal from
battery negative post and isolate.
(2) Under instrument panel, remove silencer panel
below lower steering column cover.
(3) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 17).
(4) Disconnect parking brake release link at
release handle.
(5) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate.(6) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 17).
(7) Remove the upper and lower column shrouds.
(Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL)
(8) Unsnap the trim bezel on the instrument panel
between the instrument cluster and the steering col-
umn.
(9) Remove the 2 screws securing the steering col-
umn fixed shroud to the steering column (Fig. 18),
then remove the shroud.
(10) Remove the two screws holding the metal
cover in place below the shifter/ignition interlock
linkage (Fig. 19), then remove the cover.
Fig. 17 Lower Steering Column Cover And
Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
Fig. 18 Fixed Shroud Mounting
1 - SCREWS
2 - SHROUD
Fig. 19 Cover Removal/Installation
1 - IGNITION SWITCH
2 - SCREW
3 - COVER
RSCOLUMN19-17