2004 CHRYSLER VOYAGER coolant level

SHIFT SCHEDULES
As mentioned earlier, the PCM has programming
that allows it to select a variety of shift schedules.
Shift schedule selection is dependent on the follow-
ing:
²Shift lever position
²Throttle position²Engine load
²Fluid temperature
²Software level
As driving conditions change, the PCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation
Extreme ColdOil temperature at start-up below
-16É FPark, Reverse, Neutral and 2nd
gear only (prevents shifting which
may fail a clutch with frequent
shifts)
ColdOil temperature at start-up above
-12É F and below 36É F± Delayed 2-3 upshift
(approximately 22-31 mph)
± Delayed 3-4 upshift (45-53 mph)
± Early 4-3 costdown shift
(approximately 30 mph)
± Early 3-2 coastdown shift
(approximately 17 mph)
± High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
± No EMCC
WarmOil temperature at start-up above
36É F and below 80 degree F± Normal operation (upshift,
kickdowns, and coastdowns)
± No EMCC
HotOil temperature at start-up above
80É F± Normal operation (upshift,
kickdowns, and coastdowns)
± Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F± Delayed 2-3 upshift (25-32 mph)
± Delayed 3-4 upshift (41-48 mph)
± 3rd gear FEMCC from 30-48 mph
± 3rd gear PEMCC from 27-31 mph
Super OverheatOil temperature above 260É F ± All9Overheat9shift schedule
features apply
± 2nd gear PEMCC above 22 mph
± Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
8E - 14 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)

SHIFT SCHEDULES
As mentioned earlier, the TCM has programming
that allows it to select a variety of shift schedules.
Shift schedule selection is dependent on the follow-
ing:
²Shift lever position
²Throttle position²Engine load
²Fluid temperature
²Software level
As driving conditions change, the TCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation
Extreme ColdOil temperature at start-up below
-16É FPark, Reverse, Neutral and 2nd
gear only (prevents shifting which
may fail a clutch with frequent
shifts)
ColdOil temperature at start-up above
-12É F and below 36É F± Delayed 2-3 upshift
(approximately 22-31 mph)
± Delayed 3-4 upshift (45-53 mph)
± Early 4-3 costdown shift
(approximately 30 mph)
± Early 3-2 coastdown shift
(approximately 17 mph)
± High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
± No EMCC
WarmOil temperature at start-up above
36É F and below 80 degree F± Normal operation (upshift,
kickdowns, and coastdowns)
± No EMCC
HotOil temperature at start-up above
80É F± Normal operation (upshift,
kickdowns, and coastdowns)
± Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F± Delayed 2-3 upshift (25-32 mph)
± Delayed 3-4 upshift (41-48 mph)
± 3rd gear FEMCC from 30-48 mph
± 3rd gear PEMCC from 27-31 mph
Super OverheatOil temperature above 260É F ± All9Overheat9shift schedule
features apply
± 2nd gear PEMCC above 22 mph
± Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
8E - 22 ELECTRONIC CONTROL MODULESRS
TRANSMISSION CONTROL MODULE (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

8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch................. 8W-42
A/C Compressor Clutch Relay............ 8W-42
A/C Pressure Sensor................... 8W-42
A/C-Heater Control.................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Accessory Relay....................... 8W-10
Adjustable Pedals Module............... 8W-30
Adjustable Pedals Motor................ 8W-30
Adjustable Pedals Relay................ 8W-30
Adjustable Pedals Sensor............... 8W-30
Adjustable Pedals Switch............... 8W-30
Airbags............................. 8W-43
Airbag Control Module................. 8W-43
Airbag Squibs........................ 8W-43
Ambient Temperature Sensor............ 8W-49
Antenna............................ 8W-47
ATC Remote Sensor.................... 8W-42
Auto Shut Down Relay................. 8W-30
Auto Temp Control.................... 8W-42
Automatic Day/Night Mirror............. 8W-49
B-Pillar Switches...................... 8W-61
Back-Up Lamp Switch.................. 8W-51
Battery............................. 8W-20
Battery Temperature Sensor............. 8W-20
Blend Door Actuators.................. 8W-42
Blower Motors........................ 8W-42
Blower Motor Relays................... 8W-42
Blower Motor Resistor.................. 8W-42
Body Control Module................... 8W-45
Boost Pressure Sensor.................. 8W-30
Brake Fluid Level Switch............... 8W-40
Brake Lamp Switch................. 8W-30, 51
Brake Transmission Shift Interlock
Solenoid........................... 8W-31
Cabin Heater Assist................... 8W-30
Camshaft Position Sensor............... 8W-30
CD Changer......................... 8W-47
Center High Mounted Stop Lamp......... 8W-51
Cinch/Release Motors.................. 8W-61
Clockspring................. 8W-33, 41, 43, 47
Clutch Pedal Interlock Switch......... 8W-10, 30
Clutch Pedal Upstop Switch............. 8W-30
Controller Antilock Brake............... 8W-35
Crank Case Ventilation Heater........... 8W-30
Crankshaft Position Sensor.............. 8W-30
Cylinder Lock Switches................. 8W-39
Data Link Connector................... 8W-18
Defogger Relay....................... 8W-48
Door Ajar Switches.................... 8W-39
Door Courtesy Lamps.................. 8W-44
Door Lock Switches.................... 8W-61
Dosing Pump......................... 8W-30Component Page
DVD Screen.......................... 8W-47
DVD/CD Changer..................... 8W-47
ECM/PCM Relay...................... 8W-30
EGR Solenoid........................ 8W-30
Electronic Control Unit................. 8W-64
Engine Control Module................. 8W-30
Engine Coolant Temp Sensor............. 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Oil Pressure Switch.............. 8W-30
EVAP/Purge Solenoid.................. 8W-30
Evaporator Temperature Sensor.......... 8W-42
Floor Console Lamp................... 8W-44
Floor Console Power Outlet.............. 8W-41
Fog Lamps.......................... 8W-50
Folding Mirror Relay................... 8W-62
Front Blower Module.................. 8W-42
Front Cigar Lighter.................... 8W-41
Front Control Module.................. 8W-10
Front Fog Lamp Relay................. 8W-50
Front Reading Lamps/Switch............ 8W-44
Front Wiper High/Low Relay............. 8W-53
Front Wiper On/Off Relay............... 8W-53
Fuel Heater.......................... 8W-30
Fuel Heater Relay..................... 8W-30
Fuel Injectors........................ 8W-30
Fuel Pressure Sensor.................. 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 8W-30
Full Open Switches.................... 8W-61
Fuselink............................ 8W-10
Fuses............................... 8W-10
Generator........................... 8W-20
Glow Plug Relay...................... 8W-30
Glow Plugs.......................... 8W-30
Grounds............................ 8W-15
Headlamp Leveling Motors.............. 8W-50
Headlamp Switch..................... 8W-50
Headlamp Washer Pump Motor.......... 8W-53
Headlamp Washer Relay................ 8W-53
Headlamps.......................... 8W-50
Heated Seat Backs.................... 8W-63
Heated Seat Cushions.................. 8W-63
Heated Seat Modules.................. 8W-63
High Beam Lamps..................... 8W-50
High Note Horn....................... 8W-41
Hood Ajar Switch..................... 8W-39
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coil......................... 8W-30
Ignition Switch....................... 8W-10
RS8W-02 COMPONENT INDEX8W-02-1

8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module................ 8W-40-2
Body Control Module......... 8W-40-2, 3, 4, 5, 6,
7, 8, 9, 11, 12
Brake Fluid Level Switch.............. 8W-40-9
Clockspring........................ 8W-40-10
Controller Antilock Brake.......... 8W-40-10, 14
Engine Control Module.......... 8W-40-8, 10, 14
Engine Coolant Temp Sensor......... 8W-40-7, 8
Engine Oil Pressure Sensor........... 8W-40-14
Engine Oil Pressure Switch........... 8W-40-14
Front Control Module........ 8W-40-9, 10, 13, 14
Fuel Pump Module................... 8W-40-2
Fuse 24............................ 8W-40-2
G200..................... 8W-40-2, 11, 12, 13
G300.............................. 8W-40-9
Instrument Cluster........ 8W-40-2, 3, 4, 5, 6, 7,
8, 9, 11, 12, 13
Integrated Power Module........ 8W-40-2, 7, 8, 9,
10, 13, 14
Left Front Door Ajar Switch............ 8W-40-3
Left Front Door Lock Motor/Ajar Switch . . 8W-40-3Component Page
Left Sliding Door Control Module........ 8W-40-4
Left Sliding Door Latch Sensing Switch . . . 8W-40-4
Left Sliding Door Lock Motor/Ajar Switch . 8W-40-4
Left Speed Control Switch............ 8W-40-10
Liftgate Ajar Switch.................. 8W-40-3
Liftgate Cinch/Release Motor........... 8W-40-3
Message Center.................. 8W-40-6, 13
Multi-Function Switch................ 8W-40-6
Parking Brake Switch............. 8W-40-11, 12
Powertrain Control Module....... 8W-40-7, 10, 14
Right Front Door Ajar Switch........... 8W-40-3
Right Front Door Lock Motor/Ajar
Switch.......................... 8W-40-3
Right Sliding Door Control Module...... 8W-40-5
Right Sliding Door Latch Sensing Switch . . 8W-40-5
Right Sliding Door Lock Motor/Ajar
Switch.......................... 8W-40-5
Right Speed Control Switch........... 8W-40-10
Traction Control Switch............. 8W-40-7, 8
Vehicle Speed Sensor............... 8W-40-7, 8
Washer Fluid Level Switch............. 8W-40-9
RS8W-40 INSTRUMENT CLUSTER8W-40-1

(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.(4) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 2.4L9-9
ENGINE 2.4L (Continued)

(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.(4) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 3.3/3.8L9-83
ENGINE 3.3/3.8L (Continued)

OIL COOLER & LINES
DESCRIPTION
An engine oil cooler is used on 3.3/3.8L engines
(Heavy Duty Cooling Only) (Fig. 98). The cooler is a
coolant-to-oil type and mounted between the oil filter
and engine block.
OPERATION
Engine oil travels from the oil filter and into the
oil cooler. Engine oil then exits the cooler into the
main gallery. Engine coolant flows into the cooler
from the heater return tube and exits into the water
pump inlet.
REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING).
(2) Disconnect oil cooler inlet and outlet hoses
(Fig. 97).
(3) Remove oil filter.
(4) Remove oil cooler attachment fitting (Fig. 98).
(5) Remove oil cooler.
INSTALLATION
(1) Lubricate seal and position oil cooler to connec-
tor fitting on oil filter adapter (Fig. 98).NOTE: Position the flat side of oil cooler parallel to
oil pan rail.
(2) Install oil cooler attachment fitting and tighten
to 27 N´m (20 ft. lbs.) (Fig. 98).
(3) Install oil filter.
(4) Connect oil cooler inlet and outlet hoses (Fig.
97).
Fig. 96 Engine Oil Level Dipstick and Fill Locations
1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
Fig. 97 Engine Oil Cooler Hoses
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
9 - 138 ENGINE 3.3/3.8LRS
OIL (Continued)