2004 CHRYSLER VOYAGER charging

REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable.
(3) Raise vehicle and support.
(4) Remove the right front lower splash shield.
(5) Remove accessory drive belt, refer to the Cool-
ing System section for proper procedures (Fig. 4).
(6) Lower vehicle.
(7) Remove the Air Box, refer to the Engine section
for more information.
(8) Remove the decoupler pulley cover.
(9) Use Special Tool #8433 (Fig. 6) to loosen the
Generator Decoupler (Fig. 5).
(10) Remove the tool.
(11) Remove the Generator Decoupler.
INSTALLATION
(1) Install the Generator Decoupler to the genera-
tor shaft.
(2) Use Special Tool #8433 (Fig. 6) to tighten the
Generator Decoupler (Fig. 7). Refer to the torque
chart for the proper torque.
(3) Install a new decoupler pulley cover.
(4) Install the Air Box, refer to the Engine section
for more information.(5) Raise vehicle and support.
(6) Install accessory drive belt, refer to the Cooling
System section for proper procedures (Fig. 4).
(7) Install the right front lower splash shield.
(8) Lower vehicle.
(9) Connect battery negative cable.
Fig. 4 DRIVE BELT 3.3/3.8L
Fig. 5 DECOUPLER REMOVAL (LITENS)
Fig. 6 SPECIAL TOOL 8433 AND DECOUPLER
8F - 26 CHARGINGRS
GENERATOR DECOUPLER PULLEY (Continued)

VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground.
Voltage is regulated by cycling the ground path on
SBEC vehicles or the power side on the NGC vehi-
cles, to control the strength of the rotor magnetic
field. The EVR circuitry monitors system line voltage
at the PDC and calculated battery temperature or
inlet air temperature sensor (refer to Inlet Air Tem-
perature Sensor, if equipped, for more information ).
It then determines a target charging voltage. If
sensed battery voltage is lower than the target volt-
age, the PCM feeds the field winding until sensed
battery voltage is at the target voltage. A circuit in
the PCM cycles the feed side of the generator field at
250 times per second (250Hz), but has the capability
to feed the field control wire 100% of the time (full
field) to achieve the target voltage. If the charging
rate cannot be monitored (limp-in), a duty cycle of
20% is used by the PCM in order to have some gen-
erator output. Also refer to Charging System Opera-
tion for additional information.
Fig. 7 DECOUPLER INSTALLATION (Litens)
RSCHARGING8F-27
GENERATOR DECOUPLER PULLEY (Continued)

STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION.........................28
OPERATION...........................28
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST.......................28
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST........................30
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST....................32
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST...............................33SPECIFICATIONS
Torques.............................33
STARTER ...........................34
STARTER MOTOR
REMOVAL
REMOVAL - 2.4L......................34
REMOVAL - 3.3/3.8L...................35
INSTALLATION
INSTALLATION - 2.4L..................35
INSTALLATION - 3.3/3.8L................36
STARTING
DESCRIPTION
The starting system consists of:
²Starter relay
²Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
²Battery
²Battery cables
²Ignition switch and key lock cylinder
²Clutch pedal position switch (manual transmis-
sion)
²Park/neutral position switch (automatic trans-
mission)
²Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate in conjunction with one another, and must be
tested as a complete system. For correct operation of
starting/charging systems, all components used in
these 3 systems must perform within specifications.
When attempting to diagnose any of these systems, it
is important that you keep their interdependency in
mind.
The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Powertrain Control Mod-
ule (PCM). Use of an induction-type milliampere
ammeter, volt/ohmmeter, battery charger, carbon pile
rheostat (load tester), and 12-volt test lamp may be
required.
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
8F - 28 STARTINGRS

ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING .............................. 20 STARTING
............................... 30
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM DESCRIPTION ..........................1
OPERATION ............................2
DIAGNOSIS AND TESTING - BATTERY SYSTEM .............................2
CLEANING .............................4
INSPECTION ...........................6
SPECIFICATIONS ........................6
SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS .......7
BATTERY DESCRIPTION ..........................7
OPERATION ............................9
DIAGNOSIS AND TESTING - BATTERY .......9
STANDARD PROCEDURE STANDARD PROCEDURE - SPIRAL PLATEBATTERY CHARGING ..................10
STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING .....11
STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST .......................13
STANDARD PROCEDURE - IGNITION-OFF DRAW TEST .........................13
STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL .........14REMOVAL - BATTERY
...................14
INSTALLATION .........................15
BATTERY HOLDDOWN DESCRIPTION .........................15
OPERATION ...........................15
REMOVAL .............................15
INSTALLATION .........................16
BATTERY CABLES DESCRIPTION .........................16
OPERATION ...........................16
DIAGNOSIS AND TESTING - BATTERY CABLE ......................16
REMOVAL .............................18
INSTALLATION .........................18
BATTERY TRAY DESCRIPTION .........................18
OPERATION ...........................18
REMOVAL .............................19
INSTALLATION .........................19
THERMOWRAP DESCRIPTION .........................19
OPERATION ...........................19
REMOVAL .............................19
INSTALLATION .........................19
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery is standard factory-in-
stalled equipment on this model. All of the compo-
nents of the battery system are located within the
engine compartment of the vehicle. The battery sys-
tem for this vehicle covers the following related com- ponents, which are covered in further detail later in
this section of the service manual:
² Battery - The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle. ² Battery Cable - The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
RS ENGINE SYSTEMS8Fs-1

²Battery Holddown - The battery holddown
hardware secures the battery in the battery tray in
the engine compartment. ² Battery Thermowrap - The battery thermow-
rap insulates the battery to protect it from engine
compartment temperature extremes. ² Battery Tray - The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware. For battery system maintenance schedules and
jump starting procedure, see the owner's manual in
the vehicle glove box. Optionally, refer to the Lubri-
cation and Maintenance section of this manual for
the recommended battery maintenance schedules and
for the proper battery jump starting procedure. While
battery charging can be considered a maintenance
procedure, the battery charging procedure and
related information are located later in this section of
this service manual. This was done because the bat-
tery must be fully-charged before any battery system
diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service. The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is
designed to help the dealership technicians diagnose
the cause of a defective battery. Follow the instruc-
tion manual supplied with the tester to properly
diagnose a vehicle. If the instruction manual is not
available refer to the standard procedure in this sec-
tion, which includes the directions for using the
Micro 420 battery tester.
8Fs - 2 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE. 1. The electrical system
ignition-off draw is excessive.
1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
faulty. 2. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal
connections are loose or
corroded. 4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. The battery has an
incorrect size or rating for
this vehicle. 5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. The battery is faulty. 6. Test the battery using the Micro 420 battery tester. Refer to the Standard Procedures in this
section for additional test procedures. Replace
the faulty battery, as required.
7. The starting system is
faulty. 7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically
damaged. 8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
RS
BATTERY SYSTEM8Fs-3
BATTERY SYSTEM (Continued)

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED. 1. The battery has an
incorrect size or rating for
this vehicle.1. Refer to Battery System Specifications for the
proper specifications. Replace an incorrect
battery, as required.
2. The battery terminal
connections are loose or
corroded. 2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The electrical system
ignition-off draw is excessive. 3. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
battery, as required.
5. The starting system is
faulty. 5. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is
faulty. 6. Determine if the charging system is performing
to specifications. Refer to Charging System for
charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
7. Electrical loads exceed the
output of the charging
system. 7. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
8. Slow driving or prolonged
idling with high-amperage
draw loads in use. 8. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE. 1. The battery is faulty. 1. Test the battery using the Micro 420 battery
tester.. Charge or replace the faulty battery, as
required.
ABNORMAL BATTERY DISCHARGING
Any of the following conditions can result in abnor-
mal battery discharging: 1. A faulty or incorrect charging system compo-
nent. Refer to Charging System for additional charg-
ing system diagnosis and testing procedures. 2. A faulty or incorrect battery. Use Micro 420
tester and refer to Battery System for additional bat-
tery diagnosis and testing procedures. 3. A faulty circuit or component causing excessive
ignition-off draw. 4. Electrical loads that exceed the output of the
charging system. This can be due to equipment installed after manufacture, or repeated short trip
use.
5. A faulty or incorrect starting system component.
Refer to Starting System for the proper starting sys-
tem diagnosis and testing procedures. 6. Corroded or loose battery posts and/or terminal
clamps. 7. Slow driving speeds (heavy traffic conditions) or
prolonged idling, with high-amperage draw loads in
use.
CLEANING
The following information details the recommended
cleaning procedures for the battery and related com-
8Fs - 4 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)

INSPECTION
The following information details the recommended
inspection procedures for the battery and related
components. In addition to the maintenance sched-
ules found in this service manual and the owner's
manual, it is recommended that these procedures be
performed any time the battery or related compo-
nents must be removed for vehicle service. (1) Inspect the battery cable terminal clamps for
damage. Replace any battery cable that has a dam-
aged or deformed terminal clamp. (2) Inspect the battery tray and battery holddown
hardware for damage. Replace any damaged parts. (3) Slide the thermowrap off of the battery case.
Inspect the battery case for cracks or other damage
that could result in electrolyte leaks. Also, check the
battery terminal posts for looseness. Batteries with
damaged cases or loose terminal posts must be
replaced. (4) Inspect the battery thermowrap for tears,
cracks, deformation or other damage. Replace any
battery thermal guard that has been damaged. (5) Inspect the battery built-in test indicator sight
glass(if equipped) for an indication of the battery con-
dition. If the battery is discharged, charge as
required. Refer to Standard Procedures for the
proper battery built-in indicator test procedures. Also
refer to Standard Procedures for the proper battery
charging procedures.
SPECIFICATIONS
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
² Group Size - The outside dimensions and ter-
minal placement of the battery conform to standards
established by the Battery Council International
(BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
ment. ² Cold Cranking Amperage - The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
rent (in amperes) the battery can deliver for thirty
seconds at -18É C (0É F). Terminal voltage must not
fall below 7.2 volts during or after the thirty second
discharge period. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements. ² Reserve Capacity - The Reserve Capacity (RC)
rating specifies the time (in minutes) it takes for bat-
tery terminal voltage to fall below 10.5 volts, at a
discharge rate of 25 amperes. RC is determined with
the battery fully-charged at 26.7É C (80É F). This rat-
ing estimates how long the battery might last after a
charging system failure, under minimum electrical
load. ² Ampere-Hours - The Ampere-Hours (AH) rat-
ing specifies the current (in amperes) that a battery
can deliver steadily for twenty hours, with the volt-
age in the battery not falling below 10.5 volts. This
rating is also sometimes identified as the twenty-
hour discharge rating.
BATTERY CLASSIFICATIONS & RATINGS
Part Number BCI Group Size
Classification Cold Cranking
Amperage Reserve
Capacity Ampere -
Hours Load Test
Amperage
4686158AD 34 500 110 Minutes 60 250
4727159AD 34 600 120 Minutes 66 300
4727242AD DIN H6 600 120 Minutes 66 300 4868999AA 34 700 95 Minutes 50 350
8Fs - 6 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)