2004 CHRYSLER VOYAGER Service Manual

air condition snow chains spark plugs replace four wheel drive flat tire clutch

Page 473 of 2585

CHRYSLER VOYAGER 2004 Service Manual (2) Remove the nut with washer that secures the
battery hold down bracket to the battery tray and
support unit. (3) Remove the battery hold down bracket from
the battery tray and support unit.
INSTALL

(2) Remove the nut with washer that secures the
battery hold down bracket to the battery tray and
support unit. (3) Remove the battery hold down bracket from
the battery tray and support unit.
INSTALLATION
(1) Install the battery hold down bracket in the
battery tray and support unit. (2) Install the nut with washer that secures the
battery hold down bracket to the battery tray and
support unit. Torque to 20 N´m (180 in. lbs.).
BATTERY CABLES
DESCRIPTION
The battery cables are large gauge, stranded cop-
per wires sheathed within a heavy plastic or syn-
thetic rubber insulating jacket. The wire used in the
battery cables combines excellent flexibility and reli-
ability with high electrical current carrying capacity.
Refer to Wiring Diagrams in the index of this ser-
vice manual for the location of the proper battery
cable wire gauge information. A clamping type female battery terminal made of
stamped metal is attached to one end of the battery
cable wire. A square headed pinch-bolt and hex nut
are installed at the open end of the female battery
terminal clamp. Large eyelet type terminals are
crimped onto the opposite end of the battery cable
wire and then solder-dipped. The battery positive
cable wires have a red insulating jacket to provide
visual identification and feature a larger female bat-
tery terminal clamp to allow connection to the larger
battery positive terminal post. The battery negative
cable wires have a black insulating jacket and a
smaller female battery terminal clamp. The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some models. Refer to Wiring Diagramsin the
index of this service manual for the location of more
information on the various wiring circuits included in
the battery wire harness for the vehicle being ser-
viced.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical
current generated by the charging system for restor-
ing the voltage potential of the battery. The female battery terminal clamps on the ends of the battery
cable wires provide a strong and reliable connection
of the battery cable to the battery terminal posts.
The terminal pinch bolts allow the female terminal
clamps to be tightened around the male terminal
posts on the top of the battery. The eyelet terminals
secured to the opposite ends of the battery cable
wires from the female battery terminal clamps pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
The battery positive cable terminal clamp is
attached to the ends of two wires. One wire has an
eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the Integrated
Power Module (IPM), and the other wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the engine starter motor
solenoid. The battery negative cable terminal clamp
is also attached to the ends of two wires. One wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the left side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the left front fender inner shield,
near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLE
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cable. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
battery cable connection and the battery cable again
to confirm repair. When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached. EXAM-
PLE: When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.
VOLTAGE DROP TEST
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing this
8Fs - 16 BATTERY SYSTEMRS
BATTERY HOLDDOWN (Continued)

Page 474 of 2585

CHRYSLER VOYAGER 2004 Service Manual test, be certain that the following procedures are
accomplished:² The battery is fully-charged and load tested.
Refer to Standard Procedures for the proper battery
charging and load test procedures.

test, be certain that the following procedures are
accomplished:² The battery is fully-charged and load tested.
Refer to Standard Procedures for the proper battery
charging and load test procedures. ² Fully engage the parking brake.
² If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position. ² Verify that all lamps and accessories are turned
off. ² To prevent the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Intelligent Power Module (IPM), in the
engine compartment. See the fuse and relay layout
label affixed to the underside of the IPM cover for
ASD relay identification and location. (1) Connect the positive lead of the voltmeter to
the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 13). Rotate and hold the
ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
nection between the battery negative cable terminal
clamp and the battery negative terminal post.
(2) Connect the positive lead of the voltmeter to
the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable
terminal clamp (Fig. 14). Rotate and hold the ignition
switch in the Start position. Observe the voltmeter. If
voltage is detected, correct the poor connection
between the battery positive cable terminal clamp
and the battery positive terminal post. (3) Connect the voltmeter to measure between the
battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 15). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.
(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 16). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
Fig. 13 Test Battery Negative Connection Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 14 Test Battery Positive Connection Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 15 Test Battery Positive Cable Resistance -Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
RS BATTERY SYSTEM8Fs-17
BATTERY CABLES (Continued)

Page 475 of 2585

CHRYSLER VOYAGER 2004 Service Manual eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.
REMOVAL
The battery cables on this model may include

eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.
REMOVAL
The battery cables on this model may include por-
tions of wiring circuits for the generator and other
components on the vehicle. If battery cable replace-
ment is required, it will be necessary to extract the
cables out of the engine wire harness assembly. Use
care not to damage the other wires and circuits
which are also packaged into the engine wire harness
assembly. (1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off. (2) Disconnect and isolate the negative battery
cable terminal. (3) Remove the battery thermowrap (if equipped)
from the battery tray. (4) Remove the tape from the engine wire harness
assembly, to access the desired battery cable. (5) One at a time, trace and disconnect the battery
cable retaining fasteners and routing clips until the
desired cable is free from the vehicle. (6) Feed the battery cable out of the vehicle.
INSTALLATION
(1) Position the battery cable in the vehicle.
(2) One at a time, trace and install the battery
cable retaining fasteners and routing clips until the
desired cable is properly installed in the engine wire
harness assembly. (3) Install the tape on the engine wire harness
assembly. (4) Install the battery thermowrap (if equipped) on
the battery tray. (5) Connect the negative battery cable terminal.
BATTERY TRAY
DESCRIPTION
The battery is mounted in a molded plastic battery
tray and support unit located in the left front corner
of the engine compartment. The battery tray and
support unit is secured with two nuts, one is located
directly under the battery and the other is located on
the right side of the tray which also serves as a cool-
ant bottle neck retaining bolt. An additional bolt is
located directly under the battery. The battery tray and support unit also includes a
engine vacuum reservoir, located in the rear of the
unit (Fig. 17). And a drainage hose, located in the
front of the unit (Fig. 17).
OPERATION
The battery tray provides a secure mounting loca-
tion and supports the battery. The battery tray also
provides the anchor point for the battery holddown
hardware. The battery tray and the battery hold-
down hardware combine to secure and stabilize the
battery in the engine compartment, which prevents
battery movement during vehicle operation. Unre-
strained battery movement during vehicle operation
could result in damage to the vehicle, the battery, or
both. The battery tray used on this model also includes a
engine vacuum reservoir and drainage hose. The vac-
Fig. 16 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 17 RS BATTERY TRAY
1 - ENGINE VACUUM RESERVOIR
2 - BATTERY TRAY ASSEMBLY
3 - DRAINAGE HOSE
8Fs - 18 BATTERY SYSTEMRS
BATTERY CABLES (Continued)

Page 476 of 2585

CHRYSLER VOYAGER 2004 Service Manual uum reservoir provides a storage container for engine
vacuum. Refer to the engine section of the service
manual for more engine vacuum information. The
drainage hose provides means for any liquid that

uum reservoir provides a storage container for engine
vacuum. Refer to the engine section of the service
manual for more engine vacuum information. The
drainage hose provides means for any liquid that
might collect in the bottom of the battery tray to
drain under the vehicle.
REMOVAL
(1) Disconnect and isolate the negative battery
cable. (2) Remove the battery from the vehicle. Refer to
the procedure in this section. (3) Remove the battery tray retaining fasteners
(Fig. 18).
(4) Pull battery tray up far enough to disconnect
the engine vacuum harness hose from the battery
tray mounted, vacuum reservoir. (5) Remove the battery tray from the vehicle.
INSTALLATION
(1) Position the battery tray in the vehicle.
(2) Connect the engine vacuum harness hose on
the battery tray mounted vacuum reservoir. (3) Position drainage hose and install the battery
tray retaining fasteners (Fig. 18). (4) Install the battery in the vehicle. Refer to the
procedure in this section. (5) Connect the negative battery cable.
THERMOWRAP
DESCRIPTION
A one-piece slip-on thermowrap unit shields the
battery case from engine compartment heat. The
thermowrap slips over the battery case and due to its
one piece design, the battery cables must be removed
in order to install or remove the thermowrap.
OPERATION
The thermowrap protects the battery from engine
compartment temperature extremes. The tempera-
ture of the battery can affect battery life. The air
trapped in the padded material of the thermowrap
creates a dead air space, which helps to insulate the
sides of the battery case from the air temperature
found in the surrounding engine compartment.
REMOVAL
(1) Disconnect and isolate the negative battery
cable. (2) Disconnect the positive battery cable.
(3) Lift the battery thermowrap straight up to
remove from the battery.
INSTALLATION
(1) Position the thermowrap on the battery.
(2) Connect the negative and positive battery
cables.
Fig. 18 BATTERY TRAY POSITION & ORIENTATION
1 - BATTERY TRAY RETAINING FASTENERS
RS BATTERY SYSTEM8Fs-19
BATTERY TRAY (Continued)

Page 477 of 2585

CHRYSLER VOYAGER 2004 Service Manual CHARGING
TABLE OF CONTENTS
page page
CHARGING DESCRIPTION - CHARGING SYSTEM .......20
OPERATION - CHARGING SYSTEM .........20
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM .................21
SPE

CHARGING
TABLE OF CONTENTS
page page
CHARGING DESCRIPTION - CHARGING SYSTEM .......20
OPERATION - CHARGING SYSTEM .........20
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM .................21
SPECIFICATIONS GENERATOR ........................22
TORQUE ............................22
SPECIFICATIONS - BATTERY TEMPERATURE SENSOR ...............22
SPECIAL TOOLS .......................23
BATTERY TEMPERATURE SENSOR DESCRIPTION .........................23
OPERATION ...........................23
REMOVAL .............................23
GENERATOR DESCRIPTION .........................23
OPERATION ...........................23 REMOVAL
REMOVAL - 2.4L ......................23
REMOVAL - 2.5L ......................24
REMOVAL - 3.3/3.8L ...................25
INSTALLATION INSTALLATION - 2.4L ..................26
INSTALLATION - 2.5L ..................26
INSTALLATION - 3.3/3.8L ................26
GENERATOR DECOUPLER PULLEY DESCRIPTION .........................27
OPERATION ...........................27
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY ..................27
REMOVAL .............................28
INSTALLATION .........................28
VOLTAGE REGULATOR DESCRIPTION .........................29
OPERATION ...........................29
CHARGING
DESCRIPTION - CHARGING SYSTEM
The charging system consists of:
²Generator
² Decoupler Pulley (If equipped)
² Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM) ² Ignition switch (refer to the Ignition System sec-
tion for information) ² Battery (refer to the Battery section for informa-
tion) ² Ambient Air Temperature (If equipped)
² Inlet Air Temperature (calculated battery tem-
perature)(If equipped) ² Voltmeter (refer to the Instrument Cluster sec-
tion for information if equipped) ² Wiring harness and connections (refer to the
Wiring section for information) ² Accessory drive belt (refer to the Cooling section
for more information) ² Battery Temperature sensor (if equipped)
OPERATION - CHARGING SYSTEM
The charging system is turned on and off with the
ignition switch. The system is on when the engine is
running and the ASD relay is energized. The ASD
relay is energized when the PCM grounds the ASD
control circuit. This voltage is connected through the PCM or IPM (intelligent power module) (if equipped)
and supplied to one of the generator field terminals
(Gen. Source +) at the back of the generator.
The generator is driven by the engine through a
serpentine belt and pulley or decoupler pulley
arrangement. The amount of DC current produced by the gener-
ator is controlled by the EVR (field control) circuitry
contained within the PCM. This circuitry is con-
nected in series with the second rotor field terminal
and ground. An Ambient air temperature sensor is used to cal-
culate the temperature near the battery. This tem-
perature data, along with data from monitored line
voltage (battery voltage sense circuit), is used by the
PCM to vary the battery charging rate. This is done
by cycling the ground path to control the strength of
the rotor magnetic field. The PCM then compensates
and regulates generator current output accordingly
to maintain system voltage at the targeted system
voltage based on battery temperature. All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including EVR
(field control) circuitry, 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 certain failures it detects and
illuminate the (MIL) lamp. Refer to On-Board Diag-
nostics in the Electronic Control Modules(Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
8Fs - 20 CHARGINGRS

Page 478 of 2585

CHRYSLER VOYAGER 2004 Service Manual ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION) section for more DTC information.The Charging system ªBatteryº light indicates
problems with the charging system (voltage too high/
low, generator failu

ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION) section for more DTC information.The Charging system ªBatteryº light indicates
problems with the charging system (voltage too high/
low, generator failure, etc.). If an extreme condition is
indicated, the lamp will be illuminated. The signal to
activate the lamp is sent via the PCI bus circuits.
The lamp is located on the instrument panel. Refer
to the Instrument Cluster section for additional infor-
mation. The PCM uses the ambient air temperature sensor
to control the charge system voltage. This tempera-
ture, along with data from monitored line voltage, is
used by the PCM to vary the battery charging rate.
The system voltage is higher at cold temperatures
and is gradually reduced as the calculated battery
temperature increases. The ambient temperature sensor is used to control
the battery voltage based upon ambient temperature
(approximation of battery temperature). The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture.
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions. If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 40 good trip if the problem
does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBIII t
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information. A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set. ERASING DIAGNOSTIC TROUBLE CODES
The DRBIII tScan Tool must be used to erase a
DTC. The following procedures may be used to diagnose
the charging system if: ² the check gauges lamp or battery lamp is illumi-
nated with the engine running ² the voltmeter (if equipped) does not register
properly ² an undercharged or overcharged battery condi-
tion occurs. Remember that an undercharged battery is often
caused by: ² accessories being left on with the engine not
running ² a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test (Refer t o 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE) ² loose generator belt.
INSPECTION The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions. Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system. To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBIII tscan tool.
Perform the following inspections before attaching
the scan tool. (1) Inspect the battery condition. Refer to the Bat-
tery section (Refer t o 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING) for proce-
dures. (2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required. (3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) or IPM (if
equipped) for tightness in receptacles. They should be
properly installed and tight. Repair or replace as
required. (4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
RS CHARGING8Fs-21
CHARGING (Continued)

Page 479 of 2585

CHRYSLER VOYAGER 2004 Service Manual torque specifications (Refer to 8 - ELECTRICAL/
CHARGING - SPECIFICATIONS). (5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifi

Page 480 of 2585

CHRYSLER VOYAGER 2004 Service Manual SPECIAL TOOLS
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
(NGC Vehicles) The PCM incorporates a Battery
Temperature Sensor (BTS) on its circuit board.
OPERATION
The PCM uses the temperature of the battery

SPECIAL TOOLS
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
(NGC Vehicles) The PCM incorporates a Battery
Temperature Sensor (BTS) on its circuit board.
OPERATION
The PCM uses the temperature of the battery area
to control the charge system voltage. This tempera-
ture, along with data from monitored line voltage, is
used by the PCM to vary the battery charging rate.
The system voltage is higher at cold temperatures
and is gradually reduced as temperature around the
battery increases. For vehicles with 1.6L engine, there is no physical
battery temp sensor in place to detect battery temp.
Rather, an algorithm buit in PCM is employed to pre-
dict battery temp using inlet air temp, vehicle speed,
and coolant temp, among other signals. The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture. The system target voltage is 13.5 ± 14.7 volts.
However the actual voltage go below this during
heavy electrical loads and generator speeds. Also the
actual voltage can be lower than the target voltage
between the battery and the battery voltage sense
circuit, approximately 0.2 Ð 0.3 volts. The battery temperature sensor is also used for
OBD II diagnostics. Certain faults and OBD II mon-
itors are either enabled or disabled depending upon
the battery temperature sensor input (example: dis-
able purge and EGR, enable LDP). Most OBD II
monitors are disabled below 20ÉF.
REMOVAL
The battery temperature sensor is not serviced sep-
arately. If replacement is necessary, the PCM must
be replaced.
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine. The
generator produces DC voltage at the B+ terminal. If
the generator is failed, the generator assembly sub-
components (generator and decoupler pulley) must be
inspected for individual failure and replaced accord-
ingly.
OPERATION
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor. The Y type stator winding connections deliver the
induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicles electrical system
through the generator, battery, and ground terminals. Excessive or abnormal noise emitting from the gen-
erator may be caused by: ² Worn, loose or defective bearings
² Loose or defective drive pulley (2.4L) or decou-
pler (3.3/3.8L) ² Incorrect, worn, damaged or misadjusted drive
belt ² Loose mounting bolts
² Misaligned drive pulley
² Defective stator or diode
² Damaged internal fins
REMOVAL
REMOVAL - 2.4L
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable.
(3) Disconnect the Inlet Air Temperature sensor.
(4) Remove the Air Box, refer to the Engine/Air
Cleaner for more information. (5) Remove the EVAP Purge solenoid from its
bracket and reposition. (6) Disconnect the push-in field wire connector
from back of generator. (7) Remove nut holding B+ wire terminal to back
of generator. (8) Separate B+ terminal from generator.
GENERATOR DECOUPLER 8433
RS CHARGING8Fs-23
CHARGING (Continued)

Load next 8 pages

Page: < prev 1-10 ... 441-448 449-456 457-464 465-472 473-480 481-488 489-496 497-504 505-512 ... 2592 next >

OBD port remove seats radio controls headlights timing belt length