2004 CHRYSLER VOYAGER clock

grid can be repaired using a Mopar Rear Window
Defogger Repair Kit (Part Number 4267922) or
equivalent. (Refer to 8 - ELECTRICAL/HEATED
GLASS/WINDSHIELD GRID - STANDARD PROCE-
DURE).
RADIO
DESCRIPTION
Available factory-installed radio receivers for this
model include:
²AM/FM/cassette/CD (RAZ sales code)
²AM/FM/CD with CD changer control (RBK sales
code)
²AM/FM/cassette with CD changer control fea-
ture (RBB sales code)
²AM/FM/cassette/CD with rear audio (RBU sales
code)
All factory-installed radio receivers can communi-
cate on the Programmable Communications Interface
(PCI) data bus network. All factory-installed receiv-
ers are stereo Electronically Tuned Radios (ETR) and
include an electronic digital clock function.
These radio receivers can only be serviced by an
authorized radio repair station. See the latest War-
ranty Policies and Procedures manual for a current
listing of authorized radio repair stations.
OPERATION
The radio receiver operates on ignition switched
battery current that is available only when the igni-
tion switch is in the On or Accessory/Accessory Delay
positions. The electronic digital clock function of the
radio operates on fused battery current supplied
through the IOD fuse, regardless of the ignition
switch position.
For more information on the features, setting pro-
cedures, and control functions for each of the avail-
able factory-installed radio receivers, refer to the
owner's manual. For complete circuit diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, details of wire har-
ness routing and retention, connector pin-out infor-
mation and location views for the various wire
harness connectors, splices and grounds.
DIAGNOSIS AND TESTING - RADIO
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULDRESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the DRB
IIIt, refer to the appropriate Diagnostic Service
Manual.
Refer to the appropriate wiring information. The
wiring information 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 connectors, splices and grounds.
If the vehicle is equipped with remote radio
switches located on the back of the steering wheel
spokes, and the problem being diagnosed is related to
one of the symptoms listed below, be certain to check
the remote radio switches and circuits as described
in this group, prior to attempting radio diagnosis or
repair.
²Stations changing with no remote radio switch
input
²Radio memory presets not working properly
²Volume changes with no remote radio switch
input
²Remote radio switch buttons taking on other
functions
²CD player skipping tracks
²Remote radio switch inoperative.
CAUTION: The speaker output of the radio is a
ªfloating groundº system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Check the fuse(s) in the junction block and the
Integrated Power Module (IPM). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse(s).
(2) Check for battery voltage at the fuse in the
(IPM). If OK, go to Step 3. If not OK, repair the open
circuit to the battery as required.
(3) Turn the ignition switch to the ON position.
Check for battery voltage at the fuse in the junction
block. If OK, go to Step 4. If not OK, repair the open
circuit to the ignition switch as required.
(4) Turn the ignition switch to the OFF position.
Remove the radio, but do not unplug the wire har-
ness connectors. Check for continuity between the
radio chassis and a good ground. There should be
continuity. If OK, go to Step 5. If not OK, repair the
open radio chassis ground circuit as required.
(5) Connect the battery negative cable. Turn the
ignition switch to the ON position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the radio wire harness connector. If OK, go
8A - 10 AUDIORS
QUARTER GLASS INTEGRAL ANTENNA - EXPORT (Continued)

motors, and fuel pumps that have been found to be
potential sources of RFI or EMI.
OPERATION
There are two common strategies that can be used
to suppress Radio Frequency Interference (RFI) and
ElectroMagnetic Interference (EMI) radio noise. The
first suppression strategy involves preventing the
production of RFI and EMI electromagnetic signals
at their sources. The second suppression strategy
involves preventing the reception of RFI and EMI
electromagnetic signals by the audio system compo-
nents.
The use of braided ground straps in key locations
is part of the RFI and EMI prevention strategy.
These ground straps ensure adequate ground paths,
particularly for high current components such as
many of those found in the starting, charging, igni-
tion, engine control and transmission control sys-
tems. An insufficient ground path for any of these
high current components may result in radio noise
caused by induced voltages created as the high cur-
rent seeks alternative ground paths through compo-
nents or circuits intended for use by, or in close
proximity to the audio system components or circuits.
Preventing the reception of RFI and EMI is accom-
plished by ensuring that the audio system compo-
nents are correctly installed in the vehicle. Loose,
corroded or improperly soldered wire harness connec-
tions, improperly routed wiring and inadequate audio
system component grounding can all contribute to
the reception of RFI and EMI. A properly grounded
antenna body and radio chassis, as well as a shielded
antenna coaxial cable with clean and tight connec-
tions will each help reduce the potential for reception
of RFI and EMI.
REMOTE SWITCHES
DESCRIPTION
A remote radio control switch option is available on
some models. Two rocker-type switches are mounted
on the back (instrument panel side) of the steering
wheel spokes (Fig. 12). The switch on the left spoke
is the seek switch and has seek up, seek down, and
preset station advance functions. The switch on the
right spoke is the volume control switch and has vol-
ume up, and volume down functions. The switch on
the right spoke also includes a ªmodeº control that
allows the driver to sequentially select AM radio, FM
radio, cassette player, CD player or CD changer (if
equipped).
OPERATION
These switches are resistor multiplexed units that
are hard-wired to the Body Control Module (BCM)
through the clockspring. The BCM sends the proper
messages on the Programmable Communications
Interface (PCI) data bus network to the radio
receiver. For diagnosis of the BCM or the PCI data
bus, the use of a DRB IIItscan tool and the proper
Diagnostic Procedures manual are recommended. For
more information on the operation of the remote
radio switch controls, refer to the owner's manual in
the vehicle glove box.
DIAGNOSIS AND TESTING - REMOTE
SWITCHES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY 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.
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the DRB
IIIt, refer to the appropriate Diagnostic Service
Manual.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
Fig. 12 Remote Radio Switch Operational View
1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
8A - 12 AUDIORS
RADIO NOISE SUPPRESSION COMPONENTS (Continued)

CONVENTIONAL BATTERY CHARGING TIME TABLE
Charging
Amperage5 Amps10
Amps20 Amps
Open Circuit
VoltageHours Charging @ 21É C
(70É F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used if no other battery tester is
available.
Before proceeding with this test, completely charge
the battery. Refer to Standard Procedures for the
proper battery charging procedures.
(1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize.
(2) Disconnect and isolate both battery cables, neg-
ative cable first.
(3) Using a voltmeter connected to the battery
posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 9).
See the Open-Circuit Voltage Table. This voltage
reading will indicate the battery state-of-charge, but
will not reveal its cranking capacity. If a battery has
an open-circuit voltage reading of 12.4 volts orgreater, it may be load tested to reveal its cranking
capacity. Refer to Standard Procedures for the proper
battery load test procedures.
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.45 volts 75%
12.65 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position. A
normal vehicle electrical system will draw from fif-
teen to twenty-five milliamperes (0.015 to 0.025
ampere) with the ignition switch in the Off position,
and all non-ignition controlled circuits in proper
working order. Up to twenty-five milliamperes are
needed to enable the memory functions for the Pow-
ertrain Control Module (PCM), digital clock, electron-
ically tuned radio, and other modules which may
vary with the vehicle equipment.
A vehicle that has not been operated for approxi-
mately twenty-one days, may discharge the battery
to an inadequate level. When a vehicle will not be
used for twenty-one days or more (stored), remove
the IOD fuse from the Integrated Power Module
(IPM). This will reduce battery discharging.
Excessive IOD can be caused by:
²Electrical items left on.
²Faulty or improperly adjusted switches.
²Faulty or shorted electronic modules and compo-
nents.
²An internally shorted generator.
²Intermittent shorts in the wiring.
If the IOD is over twenty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected.
(1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
to automatically shut off (time out). This may take
up to twenty minutes.
(2) Disconnect the battery negative cable.
(3) Set an electronic digital multi-meter to its
highest amperage scale. Connect the multi-meter
Fig. 9 Testing Open-Circuit Voltage - Typical
RSBATTERY SYSTEM8F-13
BATTERY (Continued)

GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The Generator Decoupler is a one way clutch (Fig.
3). It is attached to the generator and replaces the
standard pulley. It is a non-serviceable item and is to
be replaced as an assembly. It is a dry operation (no
grease or lubricants). The operation of it is not tem-
perature sensitive and has a low sensitivity to elec-
trical load.
OPERATION
The generator decoupler is a one way clutch and
should be replaced as an assembly. It is designed to
help reduce belt tension fluctuation, reduce fatigue
loads, improve belt life, reduce hubloads on compo-
nents, and reduce noise.
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY
CONDITION VERIFICATION PROCEDURE POSSIBLE CAUSES CORRECTION
Does not drive
generator (Generator
not Charging)1. Start engine and allow
engine to idle.Clutch failure Replace Decoupler
2.Verify generator pulley is
rotating.
3. View generator internal fins
thru generator housing.
4. Fins either do not rotate or
rotate very erratic.
5. Rotate decoupler pulley in
clockwise direction then
quickly rotate in
counterclockwise direction to
see if clutch engages.
Noise from generator
at engine shut down.1. Start engine and allow
engine to idle.Defective decoupler
pulley bearing.Replace decoupler pulley.
2. Shutdown engine and listen
to generator.
3. Noise heard just as engine
stops. Sounds like a click.
4. Remove accessory drive
belt.
5. Verify rotation in
counterclock wise direction is
rough.
Fig. 3 GENERATOR DECOUPLER 3.3/3.8L
RSCHARGING8F-25

CONVENTIONAL BATTERY CHARGING TIME TABLECharging
Amperage 5 Amps10
Amps 20 Amps
Open Circuit Voltage Hours Charging @ 21É C (70É
F)
12.25 to 12.49 6 hours 3 hours 1.5 hours
12.00 to 12.24 10 hours 5 hours 2.5 hours
10.00 to 11.99 14 hours 7 hours 3.5 hours
Below 10.00 18 hours 9 hours 4.5 hours
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used if no other battery tester is
available. Before proceeding with this test, completely charge
the battery. Refer to Standard Procedures for the
proper battery charging procedures. (1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize. (2) Disconnect and isolate both battery cables, neg-
ative cable first. (3) Using a voltmeter connected to the battery
posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 9).
See the Open-Circuit Voltage Table. This voltage
reading will indicate the battery state-of-charge, but
will not reveal its cranking capacity. If a battery has
an open-circuit voltage reading of 12.4 volts or greater, it may be load tested to reveal its cranking
capacity. Refer to Standard Procedures for the proper
battery load test procedures.
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage 11.7 volts or less 0% 12.0 volts 25%
12.2 volts 50%
12.45 volts 75%
12.65 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position. A
normal vehicle electrical system will draw from fif-
teen to twenty-five milliamperes (0.015 to 0.025
ampere) with the ignition switch in the Off position,
and all non-ignition controlled circuits in proper
working order. Up to twenty-five milliamperes are
needed to enable the memory functions for the Pow-
ertrain Control Module (PCM), digital clock, electron-
ically tuned radio, and other modules which may
vary with the vehicle equipment. A vehicle that has not been operated for approxi-
mately twenty-one days, may discharge the battery
to an inadequate level. When a vehicle will not be
used for twenty-one days or more (stored), remove
the IOD fuse from the Integrated Power Module
(IPM). This will reduce battery discharging. Excessive IOD can be caused by:
² Electrical items left on.
² Faulty or improperly adjusted switches.
² Faulty or shorted electronic modules and compo-
nents. ² An internally shorted generator.
² Intermittent shorts in the wiring.
If the IOD is over twenty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected. (1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
to automatically shut off (time out). This may take
up to twenty minutes. (2) Disconnect the battery negative cable.
(3) Set an electronic digital multi-meter to its
highest amperage scale. Connect the multi-meter
Fig. 9 Testing Open-Circuit Voltage - Typical
RS BATTERY SYSTEM8Fs-13
BATTERY (Continued)

(11) Install accessory drive belt, refer to the Cool-
ing System section for proper procedures. (12) Install the right front lower splash shield.
(13) Lower vehicle.
(14) Install wiring harness to the oil dip stick tube
(15) Connect battery negative cable.
(16) Verify generator output rate.
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The Generator Decoupler is a one way clutch (Fig.
11). It is attached to the generator and replaces the
standard pulley. It is a non-serviceable item and is to
be replaced as an assembly. It is a dry operation (no
grease or lubricants). The operation of it is not tem-
perature sensitive and has a low sensitivity to elec-
trical load.
OPERATION
The generator decoupler is a one way clutch and
should be replaced as an assembly. It is designed to help reduce belt tension fluctuation, reduce fatigue
loads, improve belt life, reduce hubloads on compo-
nents, and reduce noise.
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY
CONDITION VERIFICATION PROCEDURE POSSIBLE
CAUSESCORRECTION
Does not drive generator
(Generator not Charging) 1. Start engine and allow engine to idle. Clutch failure Replace Decoupler
2.Verify generator pulley is rotating.
3. View generator internal fins thru
generator housing.
4. Fins either do not rotate or rotate very
erratic.
5. Rotate decoupler pulley in clockwise
direction then quickly rotate in
counterclockwise direction to see if clutch
engages.
Noise from
generator at engine
shut down. 1. Start engine and allow engine to idle. Defective decoupler
pulley bearing.Replace decoupler
pulley.
2. Shutdown engine and listen to generator.
3. Noise heard just as engine stops.
Sounds like a click.
4. Remove accessory drive belt.
5. Verify rotation in counterclock wise
direction is rough.
Fig. 11 GENERATOR DECOUPLER 3.3/3.8L
RS CHARGING8Fs-27
GENERATOR (Continued)

HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 1
HORN
DIAGNOSIS AND TESTING - HORN..........3REMOVAL.............................4
INSTALLATION..........................5
HORN SWITCH
DESCRIPTION..........................5
HORN SYSTEM
DESCRIPTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, REFER TO ELECTRICAL, RESTRAINTS FOR
SAFETY PRECAUTIONS. DISCONNECT THE NEGA-
TIVE CABLE FROM THE BATTERY BEFORE SER-
VICING COMPONENTS INVOLVING THE AIRBAG
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG
AND PERSONAL INJURY CAN RESULT.
The horn circuit consists of a horn switch, clock-
spring, horn relay, horns and Integrated Power Mod-
ule (IPM). The horn switch is a membrane switch
located in the airbag trim cover. The horns are
located forward of the left front wheel behind the
bumper fascia.
OPERATION
The horn relay plugs into the Integrated Power
Module (IPM) which is located in the engine com-
partment. For circuit information and component
locations, refer to the appropriate wiring information.
The wiring information 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 connectors, splices and grounds.
The horns will not function if the switch is
ªCLOSEDº for more than 30 seconds. Once the
switch is ªOPENº, a 20±30 second delay will occur
before the horns are functional again.
DIAGNOSIS AND TESTING - HORN SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY 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.
Refer to Horn System Test below. If the horn does
not sound, check horn fuse located in the Integrated
Power Module (IPM). If the fuse is blown, replace
with the correct fuse. If the horns fail to sound and
the new fuse blows when depressing the horn switch,
a short circuit in the horn or the horn wiring
between the fuse terminal and the horn is responsi-
ble, or a defective horn switch allowed the horn to
burn out is responsible.
If the fuse is OK, test horn relay (Refer to 8 -
ELECTRICAL/HORN/HORN RELAY - DIAGNOSIS
AND TESTING).
If the relay is OK, test horn. Refer to Horn System
Test.
CAUTION: Continuous sounding of horn may
cause horn failure.
Should the horn sound continuously:
²Unplug the horn relay from IPM.
²Refer to (Refer to 8 - ELECTRICAL/HORN/
HORN RELAY - DIAGNOSIS AND TESTING).
Refer to the appropriate wiring information.
RSHORN8H-1

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)