2004 CHRYSLER VOYAGER set clock

8W-45 BODY CONTROL MODULE
Component Page
A/C-Heater Control............... 8W-45-16, 19
Auto Temp Control............... 8W-45-16, 19
Automatic Day/Night Mirror........... 8W-45-11
Body Control Module . . . 8W-45-2, 3, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 15, 16, 17, 18, 19, 20
Cd Changer....................... 8W-45-17
Clockspring........................ 8W-45-17
Controller Antilock Brake............. 8W-45-13
Driver Door Courtesy Lamp........... 8W-45-15
Driver Door Lock Switch........... 8W-45-12, 15
Driver Heated Seat Module........... 8W-45-11
Dvd/Cd Changer.................... 8W-45-17
Floor Console Lamp................. 8W-45-13
Front Cigar Lighter................. 8W-45-17
Front Control Module................. 8W-45-3
Front Reading Lamps/Switch....... 8W-45-13, 15
Fuel Pump Module.................. 8W-45-15
Fuse 14............................ 8W-45-3
Fuse 19............................ 8W-45-2
Fuse 20............................ 8W-45-2
Fuse 24............................ 8W-45-2
G301............................ 8W-45-2, 8
Headlamp Switch............. 8W-45-11, 16, 20
Hood Ajar Switch................... 8W-45-12
Ignition Switch...................... 8W-45-3
Instrument Cluster.......... 8W-45-2, 16, 18, 19
Instrument Panel Switch Bank . . 8W-45-10, 11, 17,
19
Integrated Power Module..... 8W-45-2, 3, 5, 6, 13
Left B-Pillar Switch.................. 8W-45-9
Left Cylinder Lock Switch............ 8W-45-10
Left Front Door Ajar Switch............ 8W-45-9
Left Front Door Lock Motor/Ajar
Switch........................ 8W-45-7, 9
Left Liftgate Flood Lamp............. 8W-45-12
Left Mid Reading Lamp............ 8W-45-9, 14
Left Power Mirror................... 8W-45-20
Left Rear Lamp Assembly........... 8W-45-5, 6
Left Rear Reading Lamp........... 8W-45-9, 14
Left Remote Radio Switch............ 8W-45-17
Left Repeater Lamp................. 8W-45-20
Left Sliding Door Control Module..... 8W-45-8, 10
Left Sliding Door Lock Motor........... 8W-45-7Component Page
Left Sliding Door Lock Motor/Ajar
Switch........................ 8W-45-7, 8
Left Visor/Vanity Lamp.............. 8W-45-13
License Lamp....................... 8W-45-8
Liftgate Ajar Switch................. 8W-45-12
Liftgate Cinch/Release Motor.......... 8W-45-12
Memory Set Switch.................. 8W-45-4
Message Center.................... 8W-45-18
Multi-Function Switch............... 8W-45-16
Name Brand Speaker Relay............ 8W-45-3
Overhead Console................. 8W-45-4, 11
Passenger Door Courtesy Lamp........ 8W-45-15
Passenger Door Lock Switch........ 8W-45-12, 15
Passenger Folding Mirror Relay........ 8W-45-20
Passenger Heated Seat Module........ 8W-45-11
Power Folding Mirror Switch.......... 8W-45-20
Power Liftgate Module............. 8W-45-8, 12
Radio............................ 8W-45-17
Rear Auto Temp Control Switch..... 8W-45-10, 19
Rear Blower Rear Control Switch....... 8W-45-10
Rear Dome Lamp.................... 8W-45-9
Rear Wiper Motor.................... 8W-45-8
Right B-Pillar Switch................. 8W-45-9
Right Cylinder Lock Switch........... 8W-45-10
Right Front Door Ajar Switch........... 8W-45-9
Right Front Door Lock Motor/Ajar
Switch........................ 8W-45-7, 9
Right Liftgate Flood Lamp............ 8W-45-12
Right Mid Reading Lamp........... 8W-45-9, 14
Right Power Mirror................. 8W-45-20
Right Rear Lamp Assembly.......... 8W-45-5, 6
Right Rear Reading Lamp.......... 8W-45-9, 14
Right Remote Radio Switch........... 8W-45-17
Right Repeater Lamp................ 8W-45-20
Right Sliding Door Control Module.... 8W-45-8, 10
Right Sliding Door Lock Motor.......... 8W-45-7
Right Sliding Door Lock Motor/Ajar
Switch........................ 8W-45-7, 8
Right Visor/Vanity Lamp............. 8W-45-13
Sentry Key Remote Entry Module....... 8W-45-3
Thatcham Alarm Module............. 8W-45-10
Traction Control Switch.............. 8W-45-17
Trailer Tow Connector................ 8W-45-5
RS8W-45 BODY CONTROL MODULE8W-45-1

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 4).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 5).(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 4 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 5 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
POWER OUTLET (Continued)

INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 120).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install camshaft sprockets. Hold camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N´m (85 ft. lbs.) (Fig. 118).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 121).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 122).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 122) to align marks and take up belt
slack.
(5) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley. Rotate the top plateCOUNTERCLOCK-
WISE. The tensioner pulley will move against the
belt and the tensioner setting notch will eventually
start to move clockwise. Watching the movement of
the setting notch, continue rotating the top plate
counterclockwise until the setting notch is aligned
with the spring tang (Fig. 123). Using the allen
wrench to prevent the top plate from moving, torque
the tensioner lock bolt to 25 N´m (220 in. lbs.). Set-
Fig. 118 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 119 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 120 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-65
TIMING BELT AND SPROCKET(S) (Continued)

ting notch and spring tang should remain aligned
after lock nut is torqued.
(6) Remove allen wrench and torque wrench.
NOTE: Repositioning the crankshaft to the TDC
position must be done only during the CLOCKWISE
rotation movement. If TDC is missed, rotate a fur-
ther two revolutions until TDC is achieved. DO NOT
rotate crankshaft counterclockwise as this will
make verification of proper tensioner setting impos-
sible.
(7) Rotate the crankshaft CLOCKWISE two com-
plete revolutions manually for seating of the belt,
until the crankshaft is repositioned at the TDC posi-
tion. Verify that the camshaft and crankshaft timing
marks are in proper position (Fig. 124).
Fig. 121 Camshaft Sprocket Alignment
1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATION
Fig. 122 Timing Belt Installation
1 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
2 - CRANKSHAFT AT TDC
3 - INSTALL BELT IN THIS DIRECTION
4 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
Fig. 123 Timing Belt Tension Adjustment
1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK BOLT
5 - SETTING NOTCH
6 - SPRING TANG
9 - 66 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)

VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 132).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 132).(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 133).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 134) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 135).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
136).
(15) Remove the engine mount bracket (Fig. 136).
Fig. 132 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 153

VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Measure valve stem-to-guide clearance as fol-
lows:
(3) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(4) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 17).
(5) Move valve to and from the indicator. For cler-
ance specifications, (Refer to 9 - ENGINE - SPECIFI-
CATIONS).
NOTE: Replace cylinder head if stem-to-guide clear-
ance exceeds specifications, or if guide is loose in
cylinder head.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Install valve spring seat on head (Fig. 19).
(3) Install new seals on all valve stems and over
valve guides (Fig. 19). Install valve springs and valve
retainers (Fig. 19).
(4) Install the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
INSTALLATION)
VALVE SPRINGS
DESCRIPTION
There are two interchangeable, floating (spring
rotates during operation), valve spring designs. Type
A may be identified by the counterclockwise (spring
spirals down and to the left) appearance, And Type B
may be identified by the clockwise (spring spirals
down and to the right) appearance. Both of the valve
springs are a bee-hive shaped design but have differ-
ent specifications (Fig. 18). The springs are seated on
a steel washer on the cylinder head with retainers
and locks retaining the springs (Fig. 19). The springs
are installed with the smaller diameter against
spring retainer (Fig. 18).
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
Fig. 16 Intake and Exhaust Valves
1 - MARGIN
2-FACE
3 - STEM
4 - VALVE SPRING RETAINER LOCK GROOVES
Fig. 17 Measuring Valve Guide Wear - Typical
Fig. 18 Valve Spring - Type A
1 - VALVE SPRING (TOP - SMALLER DIAMETER)
RSENGINE 3.3/3.8L SUPPLEMENT9s-23
INTAKE/EXHAUST VALVES & SEATS (Continued)

(7) Install a spark plug adapter in the spark plug
hole. Connect air hose that can supply 620.5±689 kPa
(90±100 psi) of air pressure to adapter. This is to
hold valves in place while servicing components.
(8) Locate the forcing screw and spring retainer
adapter assembly over the spring requiring removal
(Fig. 21).
(9) Slowly turn the forcing screw clockwise (com-
pressing the valve spring) until the valve keepers can
be removed.
(10) Turn forcing screw counterclockwise to relieve
spring tension. Remove retainer and valve spring.
(11) Repeat procedure for each cylinder requiring
valve spring removal.
INSPECTION
NOTE: The are two different types of valve springs
used that are interchangable, but have different
specifications(Refer to 9 - ENGINE/CYLINDER
HEAD/VALVE SPRINGS - DESCRIPTION).
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 22).As an example;the compression
length of a spring to be tested is 38.00 mm (1.496
in.). Turn the table of Tool C-647 until surface is in
line with the 38.00 mm (1.496 in.) mark on the
threaded stud and the zero mark on the front. Placespring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to Engine Specifications to obtain
specified height and allowable tensions (Refer to 9 -
ENGINE - SPECIFICATIONS). Replace any springs
that do not meet specifications.
Fig. 20 VALVE SPRING - REMOVE/INSTALL
1 - SPECIAL TOOL C-3422-D SPRING COMPRESSOR
2 - SPECIAL TOOL 8464 ADAPTER
Fig. 21 VALVE SPRING - REMOVE/INSTALL (HEAD
ON)
1 - SPECIAL TOOL 8453
2 - BOLTS - SPECIAL TOOL ATTACHING
3 - AIR SUPPLY HOSE ADAPTER
Fig. 22 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
RSENGINE 3.3/3.8L SUPPLEMENT9s-25
VALVE SPRINGS (Continued)

unique wheel weights. They are designed to fit the
contour of the wheel (Fig. 1).
²Inspect tires and wheels for damage, mud pack-
ing and unusual wear; correct as necessary.
²Check and adjust tire air pressure to the pres-
sure listed on the label attached to the rear face of
the driver's door.
ROAD TEST
Road test vehicle on a smooth road for a least five
miles to warm tires (remove any flat spots). Lightly
place hands on steering wheel at the 10:00 and 2:00
positions while slowly sweeping up and down from 90
to 110 km/h (55 to 70 mph) where legal speed limits
allow.
Observe the steering wheel for:
²Visual Nibble (oscillation: clockwise/counter-
clockwise, usually due to tire imbalance)
²Visual Buzziness (high frequency, rapid vibra-
tion up and down)
To rule out vibrations due to brakes or powertrain:
²Lightly apply brakes at speed; if vibration occurs
or is enhanced, vibration is likely due to causes other
than tire and wheel assemblies.
²Shift transmission into neutral while vibration
is occurring; if vibration is eliminated, vibration is
likely due to causes other than tire and wheel assem-
blies.
For brake vibrations, (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/ROTORS -
DIAGNOSIS AND TESTING).
For powertrain vibrations, (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE - DIAGNOSIS AND TEST-
ING).
For tire and wheel assembly vibrations, continue
with this diagnosis and testing procedure.
TIRE AND WHEEL BALANCE
(1) Balance the tire and wheel assemblies as nec-
essary following the wheel balancer manufacturer's
instructions and using the information listed in Stan-
dard Procedure - Tire And Wheel Balance. (Refer to
22 - TIRES/WHEELS - STANDARD PROCEDURE)
(2) Road test the vehicle for at least 5 miles, fol-
lowing the format described in Road Test.
(3) If the vibration persists, continue with this
diagnosis and testing procedure.
TIRE AND WHEEL RUNOUT/MATCH MOUNTING
(1)System Radial Runout.This on-the-vehicle
system check will measure the radial runout includ-
ing the hub, wheel and tire.
(a) Raise vehicle so tires clear floor. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(b) Apply masking tape around the circumfer-
ence of the tire in the locations to be measured
(Fig. 2). Do not overlap the tape.
(c) Check system runout using Dial Indicator
Set, Special Tool C-3339A with 25-W wheel, or
equivalent. Place the end of the indicator against
each taped area (one at a time) (Fig. 2) and rotate
the tire and wheel. System radial runout should
not exceed 0.76 mm (0.030 inch) with no tread
ªdipsº or ªsteps.º Tread ªdipsº and ªstepsº can be
identified by spikes of the dial indicator gauge.
²Tread9dips9; Rapid decrease then increase in
dial indicator reading over 101.6 mm (4.0 inch) of
tread circumference.
²Tread9steps9; Rapid decrease or increase in dial
indicator reading over 101.6 mm (4.0 inch) of tread
circumference.
(d) If system runout is excessive, re-index the
tire and wheel assembly on the hub. Remove
assembly from vehicle and install it back on the
hub two studs over from original mounting posi-
tion. If re-indexing the tire and wheel assembly
corrects or reduces system runout, check hub
runout and repair as necessary (Refer to 5 -
BRAKES - BASE/HYDRAULIC/MECHANICAL/
ROTORS - DIAGNOSIS AND TESTING).
(e) If system runout is still excessive, continue
with this diagnosis and testing procedure.
(2)Tire and Wheel Assembly Radial Runout.
This radial runout check is performed with the tire
and wheel assembly off the vehicle.
(a) Remove tire and wheel assembly from vehicle
and install it on a suitable wheel balancer.
(b) Check system runout using Dial Indicator
Set, Special Tool C-3339A with 25-W wheel, or
equivalent. Place the end of the indicator against
each taped area (one at a time) (Fig. 2) and rotate
the tire and wheel. Radial runout should not
Fig. 1 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
22 - 2 TIRES/WHEELSRS
TIRES/WHEELS (Continued)