2004 CHRYSLER VOYAGER airbag

HORN SYSTEM TEST
CONDITION POSSIBLE CAUSE CORRECTION
HORN SOUNDS CONTINUOUSLY.
NOTE: IMMEDIATELY UNPLUG HORN
RELAY IN THE IPM.(1) HORN RELAY
INOPERATIVE.(1) REPLACE RELAY.
(2) HORN CONTROL
CIRCUIT TO RELAY
SHORTED TO GROUND.(2) CHECK TERMINAL 85 IN IPM
FOR CONTINUITY TO GROUND. IF
CONTINUITY TO GROUND
INDICATES:
(A) STEERING WHEEL HORN
SWITCH/LEAD SHORTED TO
GROUND.
(B) WIRING HARNESS SHORTED
TO GROUND. FIND THE SHORT
AND REPAIR AS NECESSARY.
(3) PINCHED HORN
SWITCH WIRE UNDER
DRIVER AIRBAG MODULE.(3) REPLACE DRIVER AIRBAG TRIM
COVER.
(4) HORN SWITCH
INOPERATIVE.(4) REPLACE DRIVER AIRBAG TRIM
COVER.
(5) CLOCKSPRING
INOPERATIVE.(5) REPLACE CLOCKSPRING.
(6) FRONT CONTROL
MODULE INOPERATIVE.(6) REFER TO ELECTRONIC
CONTROL MODULES/FRONT
CONTROL MODULE.
HORN SOUND INTERMITTENTLY AS
THE STEERING WHEEL IS TURNED.(1) HORN RELAY
CONTROL CIRCUIT X3 IS
SHORTED TO GROUND
INSIDE STEERING
COLUMN OR WHEEL.(1) REMOVE DRIVER AIRBAG
AND/OR WHEEL. CHECK FOR
RUBBING OR LOOSE WIRE/
CONNECTOR, REPAIR AS
NECESSARY.
(2) PINCHED HORN
SWITCH WIRE UNDER
DRIVER AIRBAG MODULE.(2) REPLACE DRIVER AIRBAG TRIM
COVER.
(3) HORN SWITCH
INOPERATIVE.(3) REPLACE DRIVER AIRBAG TRIM
COVER.
(4) CLOCKSPRING
INOPERATIVE.(4) REPLACE CLOCKSPRING.
HORN DOES NOT SOUND (1) CHECK FUSE 8 IN
INTELLIGENT POWER
MODULE.(1) REPLACE FUSE IF BLOWN
REPAIR AS NECESSARY.
(2) NO VOLTAGE AT HORN
RELAY TERMINALS 30 &
86, AND FUSE IS OK.(2) NO VOLTAGE, REPAIR THE
CIRCUIT AS NECESSARY.
(3) OPEN CIRCUIT FROM
TERMINAL 85 OF THE
HORN RELAY TO HORN
SWITCH, X3 CIRCUIT.(3) REPAIR CIRCUIT AS
NECESSARY.
8H - 2 HORNRS
HORN SYSTEM (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
(4) HORN INOPERATIVE
OR DAMAGED.(4) CHECK VOLTAGE AT HORN
WHEN HORN SWITCH IS
PRESSED. IF NO VOLTAGE,
REPLACE HORN.
(5) HORN SWITCH
INOPERATIVE.(5) REPLACE DRIVER AIRBAG TRIM
COVER.
(6) CLOCKSPRING
INOPERATIVE.(6) REPLACE CLOCKSPRING.
(7) FRONT CONTROL
MODULE INOPERATIVE.(7) REFER TO ELECTRONIC
CONTROL MODULES/FRONT
CONTROL MODULE.
FUSE BLOWS WHEN HORN SOUNDS (1) SHORT CIRCUIT IN
HORN OR HORN WIRING.(1) REMOVE HORN RELAY, CHECK
FOR SHORTED HORN OR HORN
WIRING. DISCONNECT HORN WIRE
HARNESS TO ISOLATE SHORT
AND REPAIR AS NECESSARY.
(2) CLOCKSPRING
INOPERATIVE.(2) REPLACE CLOCKSPRING.
FUSE BLOWS WITHOUT BLOWING
HORN(1) SHORT CIRCUIT. (1) REMOVE RELAY, INSTALL NEW
FUSE, IF FUSE DOES NOT BLOW
REPLACE HORN RELAY. IF FUSE
BLOWS WITH RELAY REMOVED,
CHECK FOR SHORT TO GROUND
WITH OHMMETER ON CIRCUIT
BETWEEN TERMINALS 30 & 86
AND THE FUSE TERMINAL. REPAIR
AS NECESSARY.
(2) CLOCKSPRING
INOPERATIVE.(2) REPLACE CLOCKSPRING.
HORN
DIAGNOSIS AND TESTING - HORN
HORN
(1) Disconnect wire connector at horn.
(2) Using a voltmeter, connect one lead to ground
terminal and the other lead to the positive wire ter-
minal (Fig. 1).
(3) Depress the horn switch, battery voltage
should be present.
(4) If no voltage, refer toHORNS WILL NOT
SOUND. If voltage is OK, go to step Step 5.
(5) Using ohmmeter, test ground wire for continu-
ity to ground.
(6) If no ground repair as necessary.
(7) If wires test OK and horn does not sound,
replace horn.
HORNS SOUND CONTINUOUSLY
CAUTION: Continuous sounding of horns may
cause relay to fail.
The horn switch (membrane) sometimes can be the
cause without the switch being depressed.
(1) Remove the horn relay from the intelligent
power module.
(2) Using a continuity tester, test continuity from
the X3 cavity of the horn relay to ground. Refer to
the appropriate wiring information. The wiring infor-
mation 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 con-
nectors, splices and grounds.
(a) If continuity is detected, proceed to step Step
3.
(b) If NO continuity, replace the horn relay.
(3) Remove the airbag trim cover from the steering
wheel and disengage horn connector.
RSHORN8H-3
HORN SYSTEM (Continued)

(4) Install horn relay into Integrated Power Mod-
ule (IPM).
(a) If horn does not sound, replace airbag trim
cover.
(b) If horn sounds, repair grounded X3 circuit
from IPM to clockspring in the steering column.
HORNS WILL NOT SOUND
Check horn fuse#8intheIPM. If fuse is blown,
check for a shorted switch in the airbag module. and
refer to FUSE BLOWN section. If fuse is OK, refer to
FUSE OK section.
FUSE BLOWN
(1) Verify condition of battery terminals and volt-
age, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
- DIAGNOSIS AND TESTING). If battery connec-
tions and battery charge is OK proceed to Step 2.
(2) Using a voltmeter, test for battery voltage at
both sides of horn fuse 7. If voltage is OK, on both
sides of fuse, proceed to Fuse OK. If voltage is OK,
on one side of fuse, the fuse is blown, proceed to Step
3.
(3) Using a suitable ammeter in place of the fuse,
test amperage draw of the horn circuit. If amperage
draw is greater than 20 amps without the horn
switch depressed, a grounded circuit exists between
the fuse and the horn relay. Proceed to Step 4. If
amperage draw is greater than 20 amps with the
horn switch depressed, a grounded circuit exists
between the horn relay and the horn. Proceed to step
Step 5.
(4) Remove the horn relay from the IPM. If the
amperage draw drops to 0 amps, the horn switch or
circuit is shorted. If the amperage draw does not
drop to 0 amps, repair short at the IPM.
(5) Disengage a wire connector from one of the
horns. If amperage drops and the connected horn
sounds, replace the faulty horn. If amperage does not
drop with both horns disconnected and the horn
switch depressed, proceed to Step 6.
(6) Using a continuity tester, with the horns dis-
connected test continuity of the X2 cavity of the horn
relay to ground. If continuity is detected, the circuit
is grounded between the Junction Block and the
horns. Locate and repair pinched harness.
FUSE OK
(1) Remove the horn relay from the intelligent
power module.
(2) Using a continuity tester, Depress horn switch
and test continuity from the X3 cavity of the horn
relay to ground.
(a) If continuity is detected, proceed to Step 3.
(b) If NO continuity, proceed to Step 4.(3) Using a suitable jumper wire, jump across the
fuse F62 cavity and the X2 cavity of the horn relay in
the Junction Block.
(a) If the horn sounds, replace the horn relay.
(b) If the horn does not sound, proceed to Step 4.
(4) Remove airbag trim cover from steering wheel.
Refer to ELECTRICAL, RESTRAINTS.
(5) Test continuity across horn switch connectors
with horn switch depressed.
(a) If continuity is detected, repair open circuit
between the relay and the horn switch.
(b) If NO continuity, replace airbag trim cover.
(6) Install horn relay into intelligent power mod-
ule.
(7) Disengage wire connectors from horns.
(8) Using a voltmeter, with the horn switch
depressed test voltage across horn connector termi-
nals of the wire harness (Fig. 1).
(a) If voltage is detected, replace horns.
(b) If NO voltage, proceed to step Step 9.
(9) With the horn switch depressed, test for volt-
age between the X2 circuit and ground.
(a) If voltage OK, repair system ground at right
cowl area.
(b) If NO voltage, repair open X2 circuit between
the relay and the horns.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Hoist and support the front of the vehicle on
safety stands.
(3) From behind the front fascia and forward of
the left front wheel, disconnect the wire connectors
from horn.
(4) Remove the mounting bracket attaching nut
from the bottom of radiator closure panel. Do not
remove the horn from mounting bracket.
(5) Separate the horn(s) from vehicle.
Fig. 1 Horn Connector
8H - 4 HORNRS
HORN (Continued)

INSTALLATION
(1) Install the horns to the vehicle.
(2) Install the mounting bracket fastener.
(3) Reconnect the wire connectors to the horns.
(4) Lower the vehicle.
(5) Reconnect the battery negative cable.
HORN SWITCH
DESCRIPTION
The horn switch is molded into the airbag trim
cover. The horn switch can not be serviced separately.
For service procedures (Refer to 8 - ELECTRICAL/
RESTRAINTS/AIRBAG COVER - REMOVAL).
RSHORN8H-5
HORN (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS.........................2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS...........................2REMOVAL.............................10
INSTALLATION.........................10
CLUSTER LENS
REMOVAL.............................10
INSTALLATION.........................10
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The Mechanical Instrument Cluster (MIC) with a
tachometer is equipped with a electronic vacuum flu-
orescent transmission range indicator (PRND3L),
odometer, and trip odometer display.
The MIC without a tachometer is equipped with a
Light Emitting Diode (LED) transmission range indi-
cator (PRND3L) and a vacuum fluorescent odometer
display.
The MIC is equipped with the following warning
lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Oil Pressure
²MIL (Malfunction Indicator Lamp)
²VTSS/SKIS Indicator
²Airbag
²Traction Control
²Autostick
The MIC without a tachometer also has the follow-
ing warning lamps:
²Turns Signals
²High Beam
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Lamp is located in the message
center. When moisture is found within the fuel sys-
tem, the sensor sends a message via the PCI data
bus to the instrument cluster. The MIC illuminates
the bulb in the message center, The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RSINSTRUMENT CLUSTER8J-1

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-DIAGNOSTICS
The instrument clusters are equipped with a self
diagnostic test feature to help identify electronic prob-
lems. Prior to any test, perform the Self-Diagnostic
Test. The self diagnostic system displays instrument
cluster stored fault codes in the odometer display,
sweeps the gauges to the calibration points, and bulb
checks the warning indicators. When the key is in the
ON position with the engine not running, the MIL will
remain illuminated for regulatory purposes.
To activate the Self-Diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP ODOMETER RESET button.
(2) Continue to hold the TRIP ODOMETER
RESET button untilSofand a number (software ver-
sion number (i.e.Sof 3.2) appears in the odometer
window then release the button. If a fault code is
present, the cluster will display it in the odometer
display. When all fault codes have been displayed,
the cluster will displayªendºin the odometer dis-
play. Refer to the INSTRUMENT CLUSTER DTC'S
table to determine what each trouble code means.
INSTRUMENT CLUSTER DTC'S
DTC DESCRIPTION
100.0 LOOP-BACK FAILURE
100.1 ABS COMMUNICATION FAULT
100.2 BCM COMMUNICATION FAULT
100.3 EATX COMMUNICATION FAULT
100.4 FCM COMMUNICATION FAULT
100.5 ORC COMMUNICATION FAULT
100.6SBEC/DEC/MCM COMMUNICATION
FAULT
200.0 AIRBAG LED SHORT
200.1 AIRBAG LED OPEN
200.2 ABS LED SHORT
200.3 ABS LED OPEN
200.6 EL INVERTER TIME-OUT
200.7 EATX MISMATCH
400.0 EEPROM READ/WRITE FAILURE
400.1IMPROPER POWER DOWN
DETECTED
CALIBRATION TEST
The CLUSTER CALIBRATION table contains the
proper calibration points for each gauge. If the gauge
pointers are not calibrated, a problem exists in the
cluster. If any gauge is out of calibration, replace the
cluster.
CLUSTER CALIBRATION
SPEEDOMETER CALIBRATION POINT
1 0 MPH (0 KM/H)
2 20 MPH (40 KM/H)
3 60 MPH (100 KM/H)
4 100 MPH (160 KM/H)
TACHOMETER
1 0 RPM
2 1000 RPM
3 3000 RPM
4 6000 RPM
FUEL GAUGE
1 EMPTY
2 1/4 FILLED
3 1/2 FILLED
4 FULL
TEMPERATURE
GAUGE
1 COLD
2 1/4
3 3/4
4 HOT
ODOMETER SEGMENT TEST
If a segment in the odometer does not illuminate
normally, a problem exists in the display.
ELECTRONIC TRANSMISSION RANGE INDICATOR
SEGMENT TEST
If a segment in the transmission range indicator
does not illuminate normally, a problem exists in the
display.
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS
CONDITIONS
Refer to the following tables for possible problems,
causes, and corrections.
²INSTRUMENT CLUSTER DIAGNOSIS
²SPEEDOMETER DIAGNOSIS
²TACHOMETER DIAGNOSIS
²FUEL GAUGE DIAGNOSIS
²TEMPERATURE GAUGE DIAGNOSIS
²ODOMETER DIAGNOSIS
²ELECTRONIC GEAR INDICATOR DISPLAY
DIAGNOSIS
NOTE: Always check the functionality of the cluster
by running the self test prior to troubleshooting.
8J - 2 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)

LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS.....................20
CENTER CONSOLE LAMP
REMOVAL.............................21
INSTALLATION.........................21
CENTER CONSOLE LAMP SWITCH
REMOVAL.............................21
INSTALLATION.........................21
CLUSTER ILLUMINATION LAMPS
REMOVAL.............................21
INSTALLATION.........................21
COURTESY LAMP
REMOVAL.............................21
INSTALLATION.........................21DOME/CARGO LAMP
REMOVAL.............................22
INSTALLATION.........................22
GLOVE BOX LAMP SWITCH
REMOVAL.............................22
INSTALLATION.........................22
LIFTGATE LAMP
REMOVAL.............................22
INSTALLATION.........................22
READING LAMP
REMOVAL.............................23
INSTALLATION.........................23
VANITY LAMP
REMOVAL.............................24
INSTALLATION.........................24
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
ABS LED
AIRBAG LED
ALARM SET PC74
AUTOSTICK VFD*
BRAKE SYSTEM
WARNINGLED
CONSOLE 194
CRUISE INDICATOR VFD*
DOME/RAIL LAMPS 578
DOOR AJAR INDICATOR LED
DOOR COURTESY
LAMP578
FRONT DOOR
COURTESY567
GLOVE BOX 194
HIGH BEAM INDICATOR
(BASE CLUSTER)LED
HIGH BEAM INDICATOR PC74
LAMP BULB
CLUSTER
ILLUMINATIONPC74
LIFTGATE 578
LIFTGATE AJAR LED
LOW FUEL INDICATOR LED
LOW WASHER FLUID
INDICATORLED
MIL (BASE CLUSTER) LED
MIL PC74
OIL INDICATOR (BASE
CLUSTER)LED
OIL INDICATOR PC74
OVERHEAD CONSOLE
READINGPC579
OVERDRIVE OFF
INDICATORVFD*
READING 578
SEAT BELT INDICATOR LED
TEMPERATURE
INDICATORLED
TRAC OFF INDICATOR VFD*
TURN SIGNAL
INDICATOR (BASE
CLUSTER)LED
TURN SIGNAL
INDICATORPC74
8L - 20 LAMPS/LIGHTING - INTERIORRS

POWER SEAT SYSTEM
TABLE OF CONTENTS
page page
POWER SEAT SYSTEM
DESCRIPTION
DESCRIPTION........................50
DESCRIPTION - MEMORY SYSTEM.......51
OPERATION
OPERATION - POWER SEAT SYSTEM.....52
OPERATION - MEMORY SYSTEM.........52
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER SEAT
SYSTEM............................52
DIAGNOSIS AND TESTING - MEMORY
SYSTEM............................53
DRIVER SEAT SWITCH
DESCRIPTION.........................53
OPERATION...........................54
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH............................54
REMOVAL.............................55
INSTALLATION.........................55
MEMORY SET SWITCH
DESCRIPTION.........................55
OPERATION...........................56
DIAGNOSIS AND TESTING - MEMORY
SWITCH............................56REMOVAL.............................56
INSTALLATION.........................56
PASSENGER SEAT SWITCH
DESCRIPTION.........................56
OPERATION...........................56
DIAGNOSIS AND TESTING - PASSENGER
SEAT SWITCH........................57
REMOVAL.............................57
INSTALLATION.........................57
DRIVER POWER SEAT TRACK
DESCRIPTION.........................58
OPERATION...........................58
DIAGNOSIS AND TESTING - DRIVER POWER
SEAT TRACK.........................58
REMOVAL.............................59
INSTALLATION.........................59
PASSENGER POWER SEAT TRACK
DESCRIPTION.........................59
OPERATION...........................60
DIAGNOSIS AND TESTING - POWER SEAT
TRACK.............................60
REMOVAL.............................61
INSTALLATION.........................61
POWER SEAT SYSTEM
DESCRIPTION
DESCRIPTION
The power seat system option allows the driver
and front seat passenger to electrically adjust their
seating positions for optimum control and comfort
using the power seat switches located on the out-
board seat cushion side shield of each front seat. The
driver side power front seat can be adjusted in eight
different directions: up, down, front up, front down,
rear up, rear down, forward, rearward and recliner
forward and rearward. The passenger side power
front seat can be adjusted in four different directions:
forward, rearward and recliner forward and rear-
ward.
The power seat system receives battery current
through a 40 amp fuse in the Intelligent Power Mod-
ule and a 30 amp circuit breaker under the seat so
that the power seats remain operational, regardless
of the ignition switch position.WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS (Fig. 1). 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.
A eight-way driver side power seat is standard on
highline models and optional on others. This option
includes a six-way adjustable seat cushion track and
a two-way power seat back.
The eight-way driver side power seat is also avail-
able with the heated seat and/or memory seat system
that automatically positions the power seat for two
different drivers. Refer toHeated Seatsfor more
information on the heated seat option. Refer to
Description - Memory Systemin this section for
more information on the memory seat system.
8N - 50 POWER SEAT SYSTEMRS