2004 CHRYSLER VOYAGER towing

ENGINE
DIAGNOSIS AND TESTING - ENGINE COOLING
SYSTEM
Establish what driving condition caused the cooling
system complaint. The problem may be caused by an
abnormal load on the system such as the following:
prolonged idle, very high ambient temperature, slight
tail wind at idle, slow traffic speed, traffic jam, high
speed, steep grade.
DRIVING TECHNIQUES
To avoid overheating the cooling system:
(1) Idle with A/C off when temperature gauge is at
end of normal range.
(2) Do not increase engine speed for more air flow
and coolant flow because the electric motor fan sys-
tems are not responsive to engine RPM. The added
cooling from higher coolant flow rate is more than
offset by increased heat rejection (engine heat added
to coolant).
TRAILER TOWING
Consult the owner's manual under Trailer Towing
and do not exceed specified limits.
VISUAL INSPECTION
If the cooling system problem is not caused by a
driving condition, perform a visual inspection to
determine if there was a recent service or accident
repair, including the following:
²Loose/damaged water pump drive belt
²Incorrect cooling system refilling (trapped air or
low level)
²Brakes possibly dragging
²Damaged hoses
²Loose/damaged hose clamps
²Damaged/incorrect engine thermostat
²Damaged cooling fan motor, fan blade and fan
shroud
²Damaged head gasket
²Damaged water pump
²Damaged radiator
²Damaged coolant recovery system
²Damaged heater core
²Open/shorted electrical circuits
If the visual inspection reveals none of the above
as cause for a cooling system complaint, refer to the
following diagnostic charts.
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK.1. Pressure relief valve in radiator
cap is defective, or was not
properly seated.1. Check condition of radiator cap
and cap seal. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING) Replace cap as
necessary.
2. Incorrect cap was installed. 2. Replace cap as necessary.
3. Incorrect coolant mixture. 3. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE IS
READING HIGH OR HOT.1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING)
7 - 14 ENGINERS

NOTE: * Steering shudder can be expected in new
vehicles and vehicles with recent steering system
repairs. Shudder should dissipate after the vehicle
has been driven several weeks.
NOTE: ** To evaluate this condition, it may be nec-
essary to disconnect the coupling at the base of the
steering column. Turn the steering wheel and feel or
listen for internal rubbing in steering column. To
avoid damaging the column clockspring, note the
following. Before disconnecting coupling, place
tires in the straight-ahead position and center steer-
ing wheel. Once disconnected, DO NOT rotate
steering wheel more than one revolution in eitherdirection and place steering wheel in original loca-
tion before reconnecting coupling. If this position is
lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
steering column section.
NOTE: *** Increased low speed or stationary steer-
ing effort can be expected if the steering fluid is at
a high temperature. High fluid temperature usually
results from high engine rpm due to trailer towing,
ascending grades, or racing the engine for pro-
longed periods of time.
POWER STEERING FLUID
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH
VISIBLE LEAK.1. Loose power steering hose
fittings.1. Tighten the fitting to its specified torque.
2. Damaged or missing fitting seal,
gasket, or O-ring.2. Replace as necessary.
3. Power steering component
leaking.3. Repair or replace the leaking component
as required.
AERATED FLUID.* 1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level.
2. Air leak at supply hose, power
steering fluid reservoir or pump.2. Inspect for proper sealing. Repair as
necessary.
3. Cracked power steering pump
housing.3. Replace the power steering pump.
RESERVOIR FLUID
OVERFLOW AND FLUID
THAT IS MILKY IN COLOR1. Water contamination of power
steering fluid.1. Drain the power steering fluid from the
system. Flush the system with fresh clean
power steering fluid, drain, then refill to the
proper level.
NOTE: * Extremely cold temperatures may cause
power steering fluid aeration. Aeration should sub-
side as fluid warms.
19 - 8 STEERINGRS
STEERING (Continued)

TIMING CHAIN COVER - INSTALLATION . . . 9-155
TIMING CHAIN COVER - REMOVAL......9-153
TIMING CHAIN WEAR - STANDARD
PROCEDURE, MEASURING.............9-153
TIMING VERIFICATION - STANDARD
PROCEDURE, VALVE..................9-153
TIRE - DESCRIPTION.............22-13,22s-5
TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL) - INSTALLATION.....22-8
TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL) - REMOVAL........22-7
TIRE AND WHEEL ASSEMBLY (STEEL
WHEEL) - INSTALLATION...............22-8
TIRE AND WHEEL ASSEMBLY (STEEL
WHEEL) - REMOVAL...................22-8
TIRE AND WHEEL BALANCE -
STANDARD PROCEDURE................22-5
TIRE AND WHEEL MATCH MOUNTING -
STANDARD PROCEDURE................22-7
TIRE AND WHEEL ROTATION -
STANDARD PROCEDURE................22-7
TIRE AND WHEEL VIBRATION -
DIAGNOSIS AND TESTING..............22-1
TIRE INFLATION PRESSURES -
STANDARD PROCEDURE..........22-16,22s-8
TIRE LEAK REPAIRING - STANDARD
PROCEDURE...................22-17,22s-9
TIRE NOISE - DIAGNOSIS AND TESTING . . 22-14,
22s-6
TIRE PRESSURE FOR HIGH SPEED
OPERATION - STANDARD PROCEDURE . . . 22-17,
22s-9
TIRE PRESSURE MONITORING -
DESCRIPTION...................22-9,22s-1
TIRE PRESSURE MONITORING -
OPERATION.....................22-9,22s-1
TIRE PRESSURE SENSOR - DIAGNOSIS
AND TESTING..................22-10,22s-2
TIRE PRESSURE SENSOR RETRAIN -
STANDARD PROCEDURE..........22-10,22s-2
TIRE (TEMPORARY) - DESCRIPTION,
SPARE ........................22-14,22s-6
TIRE WEAR PATTERNS - DIAGNOSIS
AND TESTING..................22-16,22s-8
TIRES - CLEANING.............22-17,22s-10
TIRES - DESCRIPTION, RADIAL-PLY . 22-14,22s-6
TIRES - DESCRIPTION, REPLACEMENT . . . 22-14,
22s-6
TIRE/VEHICLE LEAD - DIAGNOSIS AND
TESTING......................22-14,22s-6
TO CYLINDER BORE FITTING -
STANDARD PROCEDURE, PISTON........9-42
TO FILLER NECK SEAL - DIAGNOSIS
AND TESTING, RADIATOR CAP...........7-27
TO GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT.............8W-01-9
TO GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT . 8W-01-10
TO USE WIRING DIAGRAMS -
DESCRIPTION, HOW................8W-01-1
TONE WHEEL - INSPECTION.............5-82
TONE WHEEL RUNOUT, SPECIFICATIONS . . . 5-79
TOOLS - 2.4L ENGINE, SPECIAL..........9-21
TOOLS - 3.3/3.8L ENGINE, SPECIAL.......9-95
TOOLS - 41TE AUTOMATIC TRANSAXLE,
SPECIAL..........................21-183
TOOLS - BASE BRAKE SYSTEM, SPECIAL . . 5-10,
5s-9
TOOLS - BATTERY SYSTEM SPECIAL
TOOLS, SPECIAL......................8F-7
TOOLS - BODY, SPECIAL...............23-13
TOOLS - COOLING SYSTEM, SPECIAL......7-6
TOOLS - EXHAUST SYSTEM, SPECIAL.....11-4
TOOLS - FRONT SUSPENSION, SPECIAL....2-3
TOOLS - FUEL, SPECIAL...........14-23,14-4
TOOLS - OVERHEAD CONSOLE, SPECIAL . . 8M-6
TOOLS - POWER DISTRIBUTION
SYSTEMS, SPECIAL................8W-97-1
TOOLS - POWER STEERING GEAR,
SPECIAL...........................19-34
TOOLS - POWER STEERING PUMP,
SPECIAL
...........................19-43
TOOLS - POWER STEERING, SPECIAL
.....19-9
TOOLS - REAR SUSPENSION, SPECIAL
....2-28
TOOLS - SDP POWER TRANSFER UNIT,
SPECIAL
............................21-8
TOOLS - WIRING/TERMINAL, SPECIAL
. 8W-01-10TOOLS, DIAGNOSIS AND TESTING -
SPECIAL............................3-34
TOOLS, SCHEMATICS AND DIAGRAMS -
SPECIAL...........................21s-89
TOOLS, SPECIAL TOOLS - BATTERY
SYSTEM SPECIAL.....................8F-7
TOOLS, SPECIFICATIONS - SPECIAL......8F-23
TOOLS, T850 TRANSAXLE - SPECIAL.......6-6
TOOLS, T850 TRANSAXLE - SPECIAL.....21-58
TOP COVER - INSTALLATION,
INSTRUMENT PANEL..................23-69
TOP COVER - REMOVAL, INSTRUMENT
PANEL.............................23-68
TOP PAD ASSEMBLY - INSTALLATION,
INSTRUMENT PANEL..................23-72
TOP PAD ASSEMBLY - REMOVAL,
INSTRUMENT PANEL..................23-71
TORQUES, SPECIFICATIONS.......8F-33,8F-35
TOUCH-UP - DESCRIPTION, PAINTED.....23-85
TOWING - STANDARD PROCEDURE.......0-29
TPM - CAUTION, SENSOR.........22-10,22s-2
TPM - DESCRIPTION, SENSOR.....22-10,22s-1
TPM - INSTALLATION, SENSOR....22-12,22s-3
TPM - OPERATION, SENSOR.......22-10,22s-2
TPM - REMOVAL, SENSOR........22-11,22s-2
TRACK - DESCRIPTION, DRIVER POWER
SEAT.........................8N-15,8N-58
TRACK - DESCRIPTION, PASSENGER
POWER SEAT..................8N-16,8N-59
TRACK - DIAGNOSIS AND TESTING,
DRIVER POWER SEAT...........8N-15,8N-58
TRACK - DIAGNOSIS AND TESTING,
POWER SEAT..................8N-17,8N-60
TRACK - INSTALLATION, BENCH SEAT . . . 23-104
TRACK - INSTALLATION, DRIVER POWER
SEAT.........................8N-16,8N-59
TRACK - INSTALLATION, FRONT SEAT
RISER - MANUAL....................23-95
TRACK - INSTALLATION, PASSENGER
POWER SEAT..................8N-18,8N-61
TRACK - OPERATION, DRIVER POWER
SEAT.........................8N-15,8N-58
TRACK - OPERATION, PASSENGER
POWER SEAT..................8N-17,8N-60
TRACK & RACK - DESCRIPTION, LOWER
DRIVE UNIT........................8N-34
TRACK & RACK - INSTALLATION,
LOWER DRIVE UNIT..................8N-34
TRACK & RACK - OPERATION, LOWER
DRIVE UNIT........................8N-34
TRACK & RACK - REMOVAL, LOWER
DRIVE UNIT........................8N-34
TRACK - REAR COVER - INSTALLATION,
FRONT SEAT........................23-96
TRACK - REAR COVER - REMOVAL,
FRONT SEAT........................23-96
TRACK - REMOVAL, BENCH SEAT.......23-104
TRACK - REMOVAL, DRIVER POWER
SEAT.........................8N-16,8N-59
TRACK - REMOVAL, FRONT SEAT RISER
- MANUAL..........................23-94
TRACK - REMOVAL, PASSENGER POWER
SEAT.........................8N-18,8N-61
TRACK BAR - DESCRIPTION.............2-46
TRACK BAR - INSTALLATION............2-46
TRACK BAR - OPERATION...............2-46
TRACK BAR - REMOVAL................2-46
TRACK MANUAL ADJUSTER -
INSTALLATION, FRONT SEAT...........23-95
TRACK MANUAL ADJUSTER - REMOVAL,
FRONT SEAT........................23-95
TRACK POWER ADJUSTER -
INSTALLATION, FRONT SEAT...........23-95
TRACK POWER ADJUSTER - REMOVAL,
FRONT SEAT........................23-95
TRACTION CONTROL SWITCH -
DIAGNOSIS AND TESTING..............5-82
TRACTION CONTROL SYSTEM -
DESCRIPTION........................5-76
TRACTION CONTROL SYSTEM -
OPERATION
..........................5-77
TRANSAXLE - ASSEMBLY, 41TE
AUTOMATIC
.......................21s-184
TRANSAXLE - ASSEMBLY, T850 MANUAL
. 21-42
TRANSAXLE - DESCRIPTION, 40TE
AUTOMATIC
........................21s-25
TRANSAXLE - DESCRIPTION, 41TE
AUTOMATIC
........................21-117TRANSAXLE - DESCRIPTION, T850
MANUAL...........................21-21
TRANSAXLE - DISASSEMBLY, 41TE
AUTOMATIC.......................21s-166
TRANSAXLE - DISASSEMBLY, T850
MANUAL...........................21-35
TRANSAXLE - INSTALLATION, T850
MANUAL...........................21-51
TRANSAXLE - OPERATION, 40TE
AUTOMATIC........................21s-27
TRANSAXLE - OPERATION, 41TE
AUTOMATIC........................21-119
TRANSAXLE - OPERATION, T850
MANUAL...........................21-24
TRANSAXLE - REMOVAL, T850 MANUAL . . 21-31
TRANSAXLE - SPECIAL TOOLS, T850.......6-6
TRANSAXLE - SPECIAL TOOLS, T850.....21-58
TRANSAXLE - SPECIFICATIONS, 41TE . . . 21-181,
21s-87
TRANSAXLE - SPECIFICATIONS, T850
MANUAL...........................21-56
TRANSAXLE FLUID - DESCRIPTION,
AUTOMATIC/MANUAL...................0-4
TRANSAXLE GENERAL DIAGNOSIS -
DIAGNOSIS AND TESTING, 41TE.......21-119
TRANSAXLE GENERAL DIAGNOSIS -
DIAGNOSIS AND TESTING, 4XTE.......21s-27
TRANSAXLE HYDRAULIC SCHEMATICS,
SCHEMATICS AND DIAGRAMS - 41TE . . . 21-169
TRANSAXLE HYDRAULIC SCHEMATICS,
SCHEMATICS AND DIAGRAMS - 4XTE . . . 21s-75
TRANSAXLE, SPECIAL TOOLS - 41TE
AUTOMATIC.........................21-183
TRANSDUCER - DESCRIPTION, A/C
PRESSURE.........................24-21
TRANSDUCER - DIAGNOSIS AND
TESTING, A/C PRESSURE..............24-22
TRANSDUCER - INSTALLATION, A/C
PRESSURE.........................24-22
TRANSDUCER - OPERATION, A/C
PRESSURE.........................24-21
TRANSDUCER - REMOVAL, A/C
PRESSURE.........................24-22
TRANSFER UNIT - DESCRIPTION,
POWER.............................21-1
TRANSFER UNIT - OPERATION, POWER....21-3
TRANSFER UNIT FLUID - DESCRIPTION,
AWD POWER..........................0-6
TRANSFER UNIT, SPECIAL TOOLS - SDP
POWER.............................21-8
TRANSMISSION CONTROL MODULE -
DESCRIPTION.......................8E-20
TRANSMISSION CONTROL MODULE -
OPERATION.........................8E-20
TRANSMISSION CONTROL RELAY -
DESCRIPTION...............21-247,21s-150
TRANSMISSION CONTROL RELAY -
OPERATION.................21-248,21s-150
TRANSMISSION OIL COOLER -
DESCRIPTION........................7-37
TRANSMISSION OIL COOLER -
INSPECTION.........................7-37
TRANSMISSION OIL COOLER -
INSTALLATION........................7-37
TRANSMISSION OIL COOLER -
REMOVAL...........................7-37
TRANSMISSION OIL COOLER LINES -
INSTALLATION........................7-38
TRANSMISSION OIL COOLER LINES -
REMOVAL...........................7-38
TRANSMISSION RANGE SENSOR -
DESCRIPTION...............21-248,21s-150
TRANSMISSION RANGE SENSOR -
INSTALLATION...............21-249,21s-152
TRANSMISSION RANGE SENSOR -
OPERATION.................21-248,21s-151
TRANSMISSION RANGE SENSOR -
REMOVAL..................21-249,21s-151
TRANSMITTER - DESCRIPTION,
UNIVERSAL
........................8M-10
TRANSMITTER - DIAGNOSIS AND
TESTING, KEYLESS ENTRY
........8N-42,8N-5
TRANSMITTER - DIAGNOSIS AND
TESTING, UNIVERSAL
................8M-10
TRANSMITTER - OPERATION,
UNIVERSAL
........................8M-10
TRANSMITTER CODES - STANDARD
PROCEDURE, ERASING
...............8M-11
36 INDEXRS
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