2004 CHRYSLER VOYAGER heater

HEATED SYSTEMS
TABLE OF CONTENTS
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HEATED GLASS........................... 1
HEATED MIRRORS......................... 6HEATED SEAT SYSTEM..................... 7
HEATED GLASS
TABLE OF CONTENTS
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HEATED GLASS
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM...................2
REAR WINDOW DEFOGGER RELAY
DESCRIPTION..........................3
OPERATION............................3REMOVAL.............................3
INSTALLATION..........................3
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION..........................4
OPERATION............................4
REAR WINDOW DEFOGGER GRID
STANDARD PROCEDURE - GRID LINE AND
TERMINAL REPAIR.....................4
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
The rear window defogger system consists of two
vertical bus bars linked by a series of grid lines fired
onto the inside surface of the rear window (Fig. 1).
The rear window defogger system is turned ON or
OFF by a control switch located on the A/C-heater
control at the center of the instrument panel and by
a rear window defogger relay timing circuit integral
to the integrated power module (IPM) (Refer to 8 -
ELECTRICAL/HEATED GLASS/REAR WINDOW
DEFOGGER SWITCH - DESCRIPTION).
Circuit protection is provided by a 40 amp fuse
located in the IPM.
Fig. 1 Rear Window Defogger - Typical
1 - REAR DEFOGGER GRID
2 - REAR WINDOW
RSHEATED SYSTEMS8G-1

OPERATION
When the rear window defogger button is
depressed to the On position, current is directed to
the rear defogger grid lines and the heated power
mirrors (if equipped). The heated grid lines heat the
glass to help clear the rear window and side mirror
surfaces of fog or frost.
The defogger system is controlled by a momentary
switch located in the A/C-heater control on the
instrument panel. A yellow indicator in the switch
will illuminate to indicate when the defogger system
is turned on. The integrated power module (IPM)
contains the defogger system control circuitry.
NOTE:
The rear window defogger turns off automat-
ically after approximately 10 minutes of initial opera-
tion. Each following activation cycle of the defogger
system will last approximately five minutes.
The defogger system will be automatically turned
off after a programmed time interval of about ten
minutes. After the initial time interval has expired, if
the defogger switch is turned on again during the
same ignition cycle, the defogger system will auto-
matically turn off after about five minutes.
The defogger system will automatically shut off if
the ignition switch is turned to the Off position, or it
can be turned off manually by depressing the defog-
ger switch a second time.
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM
The electrically heated rear window defogger oper-
ation can be checked on the vehicle in the following
manner:
(1) Turn the ignition switch to the On position.
(2) Make sure that the defogger switch is Off.
(3) Using a ammeter on the battery, turn the rear
defogger control switch to the On position, a distinct
increase in amperage draw should be noted.
(4) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent
clear glass should be detected in three to four min-
utes of operation.
(5) Using a DC voltmeter, contact the negative
lead to Point B, and the positive lead to Point A (Fig.
2). The voltmeter should read 10-14 volts.
NOTE: Illumination of the LED indicator means that
there is power available at the switch, but does not
necessarily verify system operation.
(6) If turning the defogger switch On produced no
distinct current draw on the ammeter, the problem
should be isolated in the following manner:²Confirm that the ignition switch is On.
²Make sure that the heated rear window feed
wire is connected to the terminal and that the
ground wire is in fact grounded.
²Make sure that fuse 13 (40 amp) in the inte-
grated power module (IPM) is OK.
(7) When the above steps have been completed and
the system is still inoperative, one or more of the fol-
lowing could be defective. It may be necessary to con-
nect a DRBIIItscan tool to perform further
diagnostics. Refer to Body Diagnostic Procedures.
²Rear window defogger switch in the A/C-heater
control.
²J1850 bus communication between the A/C-
heater control and the front control module (FCM).
²Rear window defogger relay in the IPM.
²Rear window defogger relay control circuity in
the IPM.
²Check for a loose wire connector or a wire
pushed out of a connector.
²Rear window grid lines (all grid lines would
have to be broken, or one of the feed wires not con-
nected for the system to be inoperative).
(8) If turning the rear window defogger switch On
produces severe voltmeter deflection, the circuit
should be closely checked for a shorting condition.
(9) If the system operation has been verified but
LED indicator does not illuminate, replace the A/C-
heater control.
(10) For detailed wiring information, refer to Wir-
ing Diagrams.
Fig. 2 Grid Line Test
1 - VOLTMETER
2 - VOLTAGE FEED (A)
3 - FEED WIRE
4 - MID-POINT (C)
5 - HEATED WINDOW GRID
6 - GROUND WIRE
7 - GROUND (B)
8G - 2 HEATED GLASSRS
HEATED GLASS (Continued)

(2) Position the rear window defogger relay into
the proper receptacle in the IPM.
(3) Align the rear window defogger relay terminals
with the terminal cavities in the IPM receptacle.
(4) Push down firmly on the rear window defogger
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install the cover onto the IPM.
(6) Reconnect the battery negative cable.
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The rear window defogger switch is integrated into
the A/C-heater control mounted in the center of the
instrument panel (Fig. 5). The rear window defogger
switch and the rear window defogger LED indicator
cannot be repaired and, if faulty or damaged, the
A/C-heater control must be replaced.
OPERATION
An LED indicator will illuminate when the rear
window defogger switch is activated. The switch
energizes the A/C-heater control module which then
requests the front control module (FCM) to activate
the rear window defogger relay via the J1850 com-
munication bus. The rear window defogger relay con-
trols the current to flow to the grids of the rear
window defogger and the heated power side view
mirrors. The defogger relay will be on for approxi-
mately 10 minutes or until the control switch or igni-
tion is turned off.
REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE - GRID LINE AND
TERMINAL REPAIR
REAR WINDOW DEFOGGER GRID LINE REPAIR
WARNING: THE REPAIR KIT CONTAINS EPOXY
RESIN AND AMINE TYPE HARDENER WHICH MAY
CAUSE SKIN OR EYE IRRITATION AND CAN BE
HARMFUL IF SWALLOWED. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR OPEN
FLAME THE CONTENTS CONTAIN FLAMMABLE
SOLVENTS. KEEP OUT OF REACH OF CHILDREN.
²DO NOT TAKE INTERNALLY, IF SWALLOWED
INDUCE VOMITING AND CALL A PHYSICIAN IMME-
DIATELY.
²IF SKIN CONTACT OCCURS, WASH AFFECTED
AREAS WITH SOAP AND WATER.
²IF EYE CONTACT OCCURS, FLUSH WITH
PLENTY OF WATER.
The repair of the grid lines is possible using the
MopartGrid Line Repair Package or an equivalent.
(1) Mask the repair area so the conductive epoxy
can be extended onto the grid line(s) or the bus bar
(Fig. 6).
(2) Follow the instructions in the repair kit for
preparing the damaged area.
(3) Remove the package separator clamp and mix
the conductive epoxy thoroughly. Fold in half and cut
the center corner to dispense the epoxy.
(4) Apply the conductive epoxy through the slit in
the masking tape. Overlap both ends of the break(s)
by 19 mm (3/4 inch).
(5) Carefully remove the masking tape from the
grid line(s).
CAUTION: To prevent the glass from fracturing, do
not allow the glass surface to exceed 204É C (400É
F).
(6) Allow the epoxy to cure 24 hours at room tem-
perature or use a heat gun with a 260É to 371É C
(500É to 700É F) range for 15 minutes. Hold the heat
gun approximately 254 mm (10 inches) from the
repaired area.
(7) After the conductive epoxy is properly cured,
verify operation of the rear window defogger.
Fig. 5 A/C-Heater Control - Typical
1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH
5 - FRONT WINDOW DEFROSTER MODE SELECTOR
8G - 4 HEATED GLASSRS
REAR WINDOW DEFOGGER RELAY (Continued)

HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION..........................6OPERATION............................6
HEATED MIRRORS
DESCRIPTION
The optional heated mirror system only operates in
concert with the rear window defogger system, and
will be automatically shut off after a programmed
time interval of about ten minutes. After the initial
time interval has expired, if the defogger switch is
turned on again during the same ignition cycle, the
heated mirror system will automatically shut off
after about five minutes.
The heated mirror system will automatically shut
off if the ignition switch is turned to the Off position,
or it can be shut off manually by pressing the rear
window defogger switch a second time.
OPERATION
When the rear window defogger switch (Fig. 1) is
in the On position, an electric heater grid located
behind the glass of each of the outside rear view mir-
rors is energized. When energized, each of these
heater grids produce heat to help clear the outside
rear view mirrors of ice, snow, or fog.
The heated mirror system is controlled by a
momentary rear window defogger switch on the A/C-
heater control. An amber indicator lamp in the
switch will illuminate to indicate when the defogger
system is turned on.
If the outside mirror heating grids are both inoper-
ative, refer to DIAGNOSIS AND TESTING - REARWINDOW DEFOGGER SYSTEM in his group. If
only one of the outside mirror heating grids is inop-
erative, Refer to 8 - ELECTRICAL/POWER MIR-
RORS - DIAGNOSIS AND TESTING.
The heating grid behind each outside mirror glass
cannot be repaired and, if faulty or damaged, the
entire power mirror assembly must be replaced.
Fig. 1 A/C-Heater Control Panel
1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH
5 - FRONT WINDOW DEFROSTER MODE SELECTOR
8G - 6 HEATED MIRRORSRS

Refer to the description of the heated seat switch
later in this section for additional information.
Hard wired circuitry connects the heated seat sys-
tem components to each other through the electrical
system of the vehicle. These hard wired circuits are
integral to several wire harnesses, which are routed
throughout the vehicle and retained by many differ-
ent methods. These circuits may be connected to each
other, to the vehicle electrical system and to the
heated seat system components through the use of a
combination of soldered splices and splice block con-
nectors. Refer to Wiring for complete system wiring
schematics. The wiring information also includes the
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
OPERATION
The heated seat system components operate on
battery current received through a fuse in the Inte-
grated Power Module (IPM) on a fused ignition
switch output (run) circuit from the Body Control
Module. The system will only operate when the igni-
tion switch is in the On position. The heated seat
system will be turned Off automatically whenever
the ignition switch is turned to any position except
On. Also, the heated seat system will not operate
when the surface temperature of the seat cushion
cover at either heated seat sensor is above the
designed temperature set points of the system. See
the owner's manual in the vehicle glove box for more
information on the features, use and operation of the
heated seat system.
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM
The most reliable, efficient, and accurate means to
diagnose the heated seat system requires the use of a
DRBIIItscan tool and the proper Diagnostic Proce-
dures manual. The DRBIIItscan tool can provide
confirmation that the PCI data bus is functional, that
all of the electronic modules are sending and receiv-
ing the proper messages on the PCI data bus, and
that the heated seat modules are receiving the
proper hard wired inputs from and relaying the
proper hard wired outputs to the Body Control Mod-
ule in order to perform its functions. Refer toWiring
Diagramsfor complete wiring schematics. The wir-
ing information also includes the proper wire and
connector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
DRIVER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 2). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switch
assembly that also includes the hazard, rear window
wiper and washer switches. The heated seat switches
each provide a resistor multiplexed signal to its
respective Heated Seat Module (HSM) through sepa-
rate hard wired circuits. Each switch has an Off,
Low, and High position so that both the driver and
the front seat passenger can select a preferred seat
heating mode. Each switch has two Light-Emitting
Diodes (LED) which light to indicate that the heater
for the seat is turned on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
depressed, the Low position is selected and the low
position LED indicator illuminates. When the right
side of the switch rocker is fully depressed, the High
position is selected and the high position LED indi-
Fig. 2 HEATED SEAT SWITCH LOCATION
1 - HEATED SEAT SWITCHES
8G - 8 HEATED SEAT SYSTEMRS
HEATED SEAT SYSTEM (Continued)

cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Each switch provides separate resistor multiplexed
hard wire inputs to its respective Heated Seat Mod-
ule (HSM) to indicate the selected switch position.
The heated seat module responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Low heat position set point is about 36É C (97É F),
and the High heat position set point is about 41É C
(105É F).
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH
For complete circuit diagrams, refer toWiring
Diagrams.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, SEAT OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CHECKING SWITCH SIGNAL AND WIRING AT THE
MODULE
(1) Disconnect and isolate the battery negative
cable.
(2) Access and disconnect the gray 4-way connector
from the heated seat module. Visually inspect wiring
terminals for damage that would prevent positive
connection. If not OK, repair or replace the necessary
components.
(3) Place the heated seat switch in the LO posi-
tion. Using an Ohmmeter, check the resistance
between cavities 2 and 3 of the gray connector noted
above. Resistance should be about 3.5 kilohms (3500
ohms). If not OK, check resistance directly at switch,
as noted below. If OK, proceed to the next step. If not
OK, replace the faulty switch.
(4) Place the heated seat switch in the HI position.
Using an ohmmeter, check the resistance between
cavities 2 and 3 of the gray connector noted above.
Resistance should be about 1.4 kilohms (1400 ohms).
If not OK, check resistance directly at switch, as
noted below. If OK, proceed. If not OK replace the
faulty switch.
(5) With the system ON in the HI position, check
for battery voltage and ground at cavities 4 and 1. If
OK, proceed with testing remaining components. If
not OK, repair open or shorted wiring.
CHECKING SWITCH ONLY
(1) Disconnect and isolate the battery negative
cable. Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL). Check for continuity between the
ground circuit cavity (#10) of the instrument panel
switch bank electrical connector and a good ground.
There should be continuity. If OK, go to Step 2. If not
OK, repair the open ground circuit to ground as
required.
(2) Reconnect the battery negative cable. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (run) cir-
cuit cavity of the instrument panel switch bank con-
nector (#4). If OK, turn the ignition switch to the Off
position, and go to Step 3. If not OK, repair the open
fused ignition switch output (run) circuit as required.
(3) Test the heated seat switch as shown in the
Heated Seat Switch Test chart and the connector pin-
out below (Fig. 3). If OK, go to Step 4. If not OK,
replace the faulty switch bank assembly.
DRIVER HEATED SEAT SWITCH TEST
SWITCH
POSITIONRESISTANCE
BETWEENRESISTANCE
(OHMS)
Off Pin4&5OPEN
Low Pin4&53570
High Pin4&51430
All resistance values are  1%.
Fig. 3 Instrument Panel Switch Bank Connector
RSHEATED SEAT SYSTEM8G-9
DRIVER HEATED SEAT SWITCH (Continued)

(3) Connect the negative battery cable.
(4) Verify heated seat system operation.
(5) Install the appropriate seat cushion or seat
back trim cover. Make certain the seat wire harness
is correctly routed through the seat and seat back.
The excess wire between the cushion and back ele-
ments should be securely tucked between the rear of
the cushion foam and the rear carpet flap of the trim
cover.
HEATED SEAT SENSOR
DESCRIPTION
Two heated seat sensors are used per vehicle, one
in each front seat cushion heating element. The
heated seat temperature sensor is a Negative Tem-
perature Coefficient (NTC) thermistor.
The heated seat sensors cannot be repaired or
adjusted and if found to be faulty, the complete
heated seat cushion element must be replaced.
OPERATION
The temperature sensor is a NTC thermistor.
When the temperature of the seat cushion cover
rises, the resistance of the sensor decreases. The
heated seat module supplies a five-volt current to one
side of each sensor, and monitors the voltage drop
through the sensor on a return circuit. The heated
seat module uses this temperature sensor input to
monitor the temperature of the seat, and regulates
the current flow to the seat heating elements accord-
ingly.
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR
For complete circuit diagrams, refer toWiring
Diagrams.
(1) Disconnect and isolate the battery negative
cable. Disconnect the green 4-way heated seat mod-
ule wire harness connector.
(2) Using an ohmmeter, check the resistance
between cavities 2 and 3. The sensor resistance
should be between 50 kilohms at 15É C (60É F) and 2
kilohms at 30É C (85É F). If not OK, replace the
faulty seat element and sensor assembly.
PASSENGER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 6). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switchassembly that also includes the hazard, rear window
wiper and washer switches. The heated seat switches
each provide a resistor multiplexed signal to its
respective Heated Seat Module (HSM) through sepa-
rate hard wired circuits. Each switch has an Off,
Low, and High position so that both the driver and
the front seat passenger can select a preferred seat
heating mode. Each switch has two Light-Emitting
Diodes (LED) which light to indicate that the heater
for the seat is turned on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
depressed, the Low position is selected and the low
position LED indicator illuminates. When the right
side of the switch rocker is fully depressed, the High
position is selected and the high position LED indi-
cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Each switch provides separate resistor multiplexed
hard wire inputs to its respective Heated Seat Mod-
ule (HSM) to indicate the selected switch position.
The heated seat module responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Fig. 6 HEATED SEAT SWITCH LOCATION
1 - HEATED SEAT SWITCHES
8G - 12 HEATED SEAT SYSTEMRS
HEATED SEAT ELEMENTS (Continued)

FIRING ORDERAUTO SHUT DOWN RELAY
DESCRIPTION
The relay is located in the Power Distribution Cen-
ter (PDC). For the location of the relay within the
PDC, refer to the PDC cover for location. Check elec-
trical terminals for corrosion and repair as necessary
OPERATION
The engine switched battery (NGC vehicles)
informs the PCM when the ASD relay energizes. A 12
volt signal at this input indicates to the PCM that
the ASD has been activated. This input is also used
to power certain drivers on NGC vehicles.
When energized, the ASD relay on NGC vehicles
provides power to operate the injectors, ignition coil,
generator field, O2 sensor heaters (both upstream
and downstream), evaporative purge solenoid, EGR
solenoid (if equipped) wastegate solenoid (if
equipped), and NVLD solenoid (if equipped).
The ASD relay also provides a sense circuit to the
PCM for diagnostic purposes. If the PCM does not
receive 12 volts from this input after grounding the
control side of the ASD relay, it sets a Diagnostic
Trouble Code (DTC). The PCM energizes the ASD
any time there is an engine speed that exceeds a pre-
determined value (typically about 50 rpm). The ASD
relay can also be energized after the engine has been
turned off to perform an O2 sensor heater test, if
vehicle is equipped with OBD II diagnostics.
As mentioned earlier, the PCM energizes the ASD
relay during an O2 sensor heater test. On NGC vehi-
cles it checks the O2 heater upon vehicle start. The
PCM still operates internally to perform several
checks, including monitoring the O2 sensor heaters.
FIRING ORDER 2.4L
Firing Order 1-2-3-4-5-6 3.3/3.8L
1 - Electrical Connector
RSIGNITION CONTROL8I-3
IGNITION CONTROL (Continued)