2004 CHRYSLER VOYAGER 8e electrical

(11) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 71). (12) If the vehicle is equipped with the 2.5L diesel
engine, install the coolant recovery pressure con-
tainer and bracket. (Refer t o 7 - COOLING/ENGINE/
COOLANT RECOVERY PRESS CONTAINER -
INSTALLATION) (13) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
the mounting nuts to a torque of 14 N´m (124 in.
lbs.). (14) Install the battery tray. Install the two nuts
and one bolt attaching the battery tray to the vehicle.
Tighten the bolt and nuts to a torque of 14 N´m (124
in. lbs.). (15) If vehicle is equipped with speed control, con-
nect the servo vacuum hose to the vacuum tank on
the battery tray. (16) Install the battery, clamp and mounting nut.
(17) Install the positive battery cable on the bat-
tery. (18) Install the negative battery cable on the bat-
tery. (19) Install the battery thermal guard shield.
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted. (20) Remove and replace the brake lamp switch
with a NEW switch. (Refer t o 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer t o 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION) (21) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE) (22) Road test vehicle to ensure proper operation
of the brakes.
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)
NOTE: Only vehicles without antilock brakes (ABS)
have a proportioning valve. Vehicles with ABS uti-
lize electronic brake distribution which is controlled
through the ABS integrated control unit.
Vehicles not equipped with ABS use a height sens-
ing proportioning valve. It is mounted to the body of the vehicle above the rear axle (Fig. 80). It has an
actuator lever that attaches to the rear axle and
moves with the axle to help the valve sense the vehi-
cle height.
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it. It is replaced as a complete assembly.
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentially
could result in increased stopping distance of the
vehicle.
OPERATION - PROPORTIONING VALVE
(HEIGHT SENSING)
Vehicles not equipped with ABS use a height sens-
ing proportioning valve. The height sensing proportioning valve operates
similarly to a standard proportioning valve in the fol-
lowing way. As hydraulic pressure is applied to the
valve, full input hydraulic pressure is supplied to the
rear brakes up to a certain pressure point, called the
split point. Beyond the split point, the proportioning
valve reduces the amount of hydraulic pressure to
the rear brakes according to a given ratio. Thus, on
light brake applications, approximately equal
hydraulic pressure will be transmitted to both the
front and rear brakes. Upon heavier brake applica-
tions, the hydraulic pressure transmitted to the rear
Fig. 80 HEIGHT SENSING PROPORTIONING VALVE
1 - PROPORTIONING VALVE
2 - ACTUATOR LEVER
3 - AXLE BRACKET
4 - REAR AXLE
RS BRAKES5s-51
POWER BRAKE BOOSTER (Continued)

(5) Install the park brake release rod on the
release mechanism of the park brake pedal. (6) Position the park brake pedal mechanism into
its installed position on the body of the vehicle. (7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 111). (8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 111). (9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 111). (10) Tighten pedal mechanism attaching bolts and
nut to 28 N´m (250 in. lbs.). (11) Verify that the park brake pedal is in the fully
released (full up) position. (12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 110).
NOTE: If the original lever assembly is being used,
the lever mechanism auto adjuster spring tension
will need to be reset. (Refer t o 5 - BRAKES/PARK-
ING BRAKE - STANDARD PROCEDURE)
(14) Lower vehicle.
(15) Remove the lock-out pin (if a new lever has
been installed) from the automatic cable adjuster on
the park brake pedal mechanism. (16) Install the electrical junction block on the
instrument panel. (17) Install the reinforcement on the lower instru-
ment panel. (18) Install the steering column lower cover on the
lower instrument panel. (19) Install the silencer panel under the instru-
ment panel. (20) Install the left side kick panel.
(21) Install the sill scuff plate on the lower sill of
the left door. (22) Install the negative (ground) cable on the bat-
tery. (23) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
LEVER - PARKING BRAKE
(EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE) (2) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 112).
(3) Remove the left rear and intermediate parking
brake cables from the parking brake cable equalizer
(Fig. 113).
(4) Remove the equalizer from the front parking
brake cable. (5) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
parking brake lever mechanism to rotate around to
its stop and remove the tension from the adjuster
and front park brake cable.
Fig. 112 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 113 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
5s - 68 BRAKESRS
LEVER - PARKING BRAKE (Continued)

(2) Install clutch release bearing to lever. Apply
grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 10).
(3) Apply grease to pivot ball, and on release lever
at slave cylinder contact point.
(4) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball(s) (Fig. 11). A ªpopº sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.
MASTER CYLINDER - RHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove master cylinder to clutch pedal pin
retainer clip. Disengage pushrod from clutch pedal
pin (Fig. 13).
(3) Disengage master cylinder grommet from cowl
panel.
(4) Remove battery and tray.
(5)Diesel models:Remove windshield wiper mod-
ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)
(6) Discharge Air Conditioning system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)(7) Remove suction/discharge line from evaporator
junction block.
(8) Using tool 6638A, disconnect clutch hydraulic
ªquick-connectº fitting (Fig. 12).
(9) Remove clutch master cylinder tubing from
retainers in engine compartment.
(10) Remove clutch master cylinder from dash
panel/clutch pedal bracket by rotating 45É clockwise
and pulling outward towards engine (Fig. 13).
(11) Carefully guide clutch master cylinder and
hydraulic plumbing from engine compartment.
Fig. 10 Release Bearing-to-Lever
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 11 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 12 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
6 - 8 CLUTCHRS
CLUTCH RELEASE LEVER AND BEARING (Continued)

INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45É counter-clockwise, secur-
ing it to pedal bracket (Fig. 13).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 13).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder ªquick connectº fitting. An audible
ªclickº should be heard. Verify connection by pulling
outward.
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8)Diesel models:Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MASTER CYLINDER - LHD
REMOVAL
(1) Disconnect battery cables.
(2) Remove instrument panel lower silencer (Fig.
14).
(3) Remove knee bolster (Fig. 15).
(4) Remove clutch master cylinder pushrod
retainer clip (Fig. 16).
(5) Disconnect pushrod from clutch pedal (Fig. 16).
(6) Remove battery shield.
(7) Remove battery.
(8) Remove battery tray.
(9) Remove windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
Fig. 13 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH RODFig. 14 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 15 Knee Bolster
1 - KNEE BOLSTER
RSCLUTCH6-9
MASTER CYLINDER - RHD (Continued)

(10) Using Tool 6638A, disconnect clutch master
cylinder ªquick connectº fitting (Fig. 17). Disengage
plumbing retainer from body stud.
(11) Remove master cylinder reservoir-to-strut
tower nuts (Fig. 18). Reposition reservoir off to side.
(12) Remove clutch master cylinder from dash
panel by rotating clockwise 45É and removing from
dash panel (Fig. 18).(13) Remove master cylinder and plumbing from
engine compartment. Use care not to bend or kink
plumbing. Note plumbing routing to aid in installa-
tion.
INSTALLATION
(1) Install master cylinder into position, while
routing plumbing as originally installed.
(2) Insert master cylinder pushrod through dash
panel (Fig. 18) and rotate 45É counter-clockwise to
secure.
(3) Connect master cylinder plumbing quick-con-
nect fitting. An audible ªclickº should be heard. Ver-
ify connection by pulling outward.
(4) Install master cylinder reservoir onto strut
tower. Install and tighten two (2) master cylinder
reservoir-to-strut tower nuts to 11 N´m (100 in. lbs.)
(Fig. 18).
(5) Install windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION).
(6) Install battery tray.
(7) Install battery.
(8) Install battery shield.
(9) Connect master cylinder pushrod to clutch
pedal lever (Fig. 16). Install retainer clip.
(10) Install knee bolster and instrument panel
lower silencer (Fig. 15) (Fig. 14).
(11) Connect battery cables.
Fig. 16 Master Cylinder Pushrod at Pedal
1 - MASTER CYLINDER PUSHROD
2 - CLUTCH/BRAKE PEDAL ASSEMBLY
3 - PUSHROD RETAINER
Fig. 17 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
Fig. 18 Clutch Master Cylinder Removal/Installation
1 - CLUTCH MASTER CYLINDER
2 - RESERVOIR
3 - NUT (2)
6 - 10 CLUTCHRS
MASTER CYLINDER - LHD (Continued)

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

CONDITION POSSIBLE CAUSES CORRECTION
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY NOT BE
READING HIGH.1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture too concentrated or
too diluted.2. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
3. Incorrect cooling system
pressure cap.3. Install correct pressure cap.
HOSE(S) COLLAPSE AS ENGINE
COOLS DOWN.1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
recovery system.1. (a) Pressure cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING)
Replace as necessary.
(b) Hose between the radiator and
overflow container is plugged or
pinched. Clean and repair as
necessary.
(c) Vent at coolant reserve/overflow
container is plugged. Clean vent
and repair as necessary.
(d) Reserve/overflow container is
internally blocked. Clean and repair
as necessary.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED).1. Radiator and/or A/C condenser is
restricted, obstructed, or dirty
(insects, leaves, etc.).1. Remove restriction and/or clean
as necessary.
2. Electrical radiator fan not
operating when A/C is operated.2. For test procedure (Refer to
appropriate Diagnostic Information).
Repair as necessary.
3. Engine is overheating (heat may
be transferred from radiator to A/C
condenser). High underhood
temperatures due to engine
overheating may also transfer heat
to A/C components.3. Correct overheating condition.
4. All models are equipped with air
seals at the radiator and/or A/C
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.4. Check for missing or damaged air
seals and repair as necessary.
INADEQUATE HEATER
PERFORMANCE.1. Check for a Diagnostic trouble
code (DTC).1. For procedures, (Refer to
appropriate Diagnostic Information).
Repair as necessary.
2. Coolant level low. 2. (Refer to 7 - COOLING -
STANDARD PROCEDURE) Repair
as necessary.
RSENGINE7-15
ENGINE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.1. Check the freeze point of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as necessary.
COOLANT LEVEL CHANGES IN
COOLANT BOTTLE.
TEMPERATURE GAUGE IS IN
NORMAL RANGE.1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
The coolant level will also drop as
the system removes air from a
recent filling.1. A normal condition. No repair is
necessary.
Refer to (Fig. 1) when using the TEMPERATURE
GAUGE INDICATION DIAGNOSIS CHART.
TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC).1. Normal reaction to fan and/or
thermostat cycle (Fig. 1 ),
Examples B and C. During cold
weather operation with the heater
blower in the high position, the
gauge reading may drop slightly
(Fig. 1 ), Example D. Fluctuation is
also influenced by outside
temperature and heavy loads (Fig.
1 ), Example E.1. A normal condition. No correction
is necessary.
2. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
(Fig. 1 ), Example F.2. A normal condition. No correction
is necessary. Gauge reading should
return to normal range (Fig. 1 ),
Example A, after vehicle is driven.
3. Gauge reading high after
restarting a warmed-up (hot)
engine.3. A normal condition. No correction
is necessary. The gauge should
return to normal range (Fig. 1 ),
Example A, after a few minutes of
engine operation.
4. Temperature gauge or engine
coolant temperature sensor
defective or shorted. Also, corroded
or loose wiring in the electrical
circuit.4. Check operation of gauge or
engine coolant temperature sensor
and repair, if necessary.
RSENGINE7-17
ENGINE (Continued)