2004 CHRYSLER VOYAGER battery location

HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.1. Loose or corroded battery
cables.1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.1. Integrated Power Module (IPM)
not controlling voltage.1. Test and repair Integrated Power Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
HEADLAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE.1. Charging system output too low. 1. Test and repair charging system, refer to
Electrical, Wiring Information.
2. Poor lighting circuit Z343/Z344-
ground.2. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z343/Z344-
ground.1. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
2. Variable resistance in headlamp
circuit.2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or
splices in circuit.3. Inspect and repair all connectors and splices,
refer to Electrical, Wiring Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
RSLAMPS/LIGHTING - EXTERIOR8L-11
HEADLAMP (Continued)

(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 15).
(2) If necessary, tape a line on the floor 10 meters
(32.8 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp cut-off line   20 mm (0.75 in.). The high beam
pattern should be correct when the low beams are
aligned properly (Fig. 15). To adjust headlamp align-
ment, rotate adjustment screws (Fig. 16) to achieve
the specified low beam cut-off location.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws (Fig. 17).
(3) Disconnect the wiring harness from the bulbs
(Fig. 18).
(4) Remove wire harness retainer from back of
headlamp unit.
(5) Remove the headlamp unit.
Fig. 14 HEADLAMP UNIT ADJUSTMENT
1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-15
HEADLAMP UNIT (Continued)

(2) Turn the ignition switch to the On position.
(3)
Following completion of these tests, the electron-
ics module will display one of the following messages:
a.Pass Self Test (EVIC only), PASS (CT,
CMTC)- The electronics module is working properly.
b.Failed Self Test (EVIC only), FAIL (CT,
CMTC)- The electronics module has an internal fail-
ure. The electronics module is faulty and must be
replaced.
c.Failed J1850 Communication (EVIC only),
BUS (CT, CMTC)- The electronics module is not
receiving proper message input through the J1850
PCI data bus circuit. This can result from one or
more faulty electronic modules in the vehicle, or from
a faulty PCI data bus. The use of a DRB IIItscan
tool and the proper Diagnostic Procedures manual
are required for further diagnosis.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earth's mag-
netic field strength, based on geographic location.
Refer to Compass Variation Adjustment in the Stan-
dard Procedures section of this group.
NOTE: If the compass reading displays dashes, and
only ªCALº appears in the display, demagnetizing
may be necessary to remove excessive residual
magnetic fields from the vehicle. Refer to Compass
Demagnetizing in the Standard Procedures section
of this group.
STANDARD PROCEDURE
STANDARD PROCEDURE - READING/
COURTESY LAMP REPLACEMENT
(1) Open hood, disconnect and isolate the negative
battery cable remote terminal from the remote bat-
tery post.
(2) Remove the reading/courtesy lamp lens. Using
a trim stick, gently pry the forward edge of the read-
ing/courtesy lamp lens outward.
(3) Remove the reading/courtesy lamp socket from
the overhead console. Rotate the reading/courtesy
lamp socket one quarter turn counter clockwise.
(4) Remove the lamp and socket assembly.
(5) Reverse the above procedure to install.
STANDARD PROCEDURE - MODULE LAMP
REPLACEMENT
(1) Remove the overhead console (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - REMOVAL).
(2) Using a flat blade screwdriver twist out socket/
lamp (Fig. 1).(3) Replace lamp(s) as necessary.
STANDARD PROCEDURE - COMPASS
CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
The electronic compass unit features a self-cali-
brating design, which simplifies the calibration pro-
cedure. This feature automatically updates the
compass calibration while the vehicle is being driven.
This allows the compass unit to compensate for small
changes in the residual magnetism that the vehicle
may acquire during normal use. If the compass read-
ings appear to be erratic or out of calibration, per-
form the following calibration procedure. Also, new
service replacement Electronic Modules (EVIC,
CMTC, CT) must have their compass calibrated
using this procedure. Do not attempt to calibrate the
compass near large metal objects such as other vehi-
cles, large buildings, or bridges; or, near overhead or
underground power lines.
NOTE: Whenever the compass is calibrated manu-
ally, the variance number must also be reset. Refer
to Compass Variation Adjustment in this group.
Fig. 1 EVIC
1 - OVERHEAD CONSOLE HOUSING
2 - EVIC/CMTC MODULE
3 - ILLUMINATION LAMPS
4 - MODULE RETAINING SCREWS
RSMESSAGE SYSTEMS8M-3
OVERHEAD CONSOLE (Continued)

US/Mpush button to step through the zone numbers,
until the zone number for your geographic location
appears in the display.
(6) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles momentarily depress and release
theRESETpush button to enter the displayed zone
number into the EVIC/CMTC module memory. On
Compass Temperature Module (CT) equipped vehicles
depress theC/Tpush button to enter the displayed
zone number into the electronic module memory.
(7) Confirm that the correct directions are now
indicated by the compass.
REMOVAL - OVERHEAD CONSOLE
(1) Disconnect and isolate the remote negative bat-
tery cable.
(2) Remove the overhead console retaining screw,
located in the front of console.
(3) Using your fingertips, grasp the sides of the
overhead console and pull straight down evenly to
disengage the two snap clips at the rear of the unit.
(4) Lower the overhead console far enough to
access the wire harness connectors.
(5) Disconnect the EVIC, CMTC or CT electronic
module and the reading/courtesy lamps electrical
connector.
(6) Remove the overhead console from the vehicle.
INSTALLATION
(1) Position the overhead console in the vehicle.
(2) Connect the EVIC, CMTC or CT electronic
module and the reading/courtesy lamps electrical
connector.
(3) Using your fingertips, grasp the sides of the
overhead console and push straight up evenly to
engage the two snap clips at the rear of the unit.
CAUTION: DO NOT PRESS ON THE SUNGLASS
STORAGE BIN DOOR. DAMAGE TO THE DOOR MAY
RESULT.
(4) Install the overhead console retaining screw,
located in the front of console. Torque the screw to
1.2 N´m (10 in. lbs.).
(5) Connect the remote negative battery cable.
SPECIAL TOOLS
OVERHEAD CONSOLE
ELECTRONIC VEHICLE INFO
CENTER
DESCRIPTION
The Electronic Vehicle Information Center (EVIC)
is a module located in the overhead console on some
models. The EVIC module features a large Vacuum
Fluorescent Display (VFD) screen for displaying
information, and back-lit push button switches
labeled C/T (compass/thermometer), RESET, STEP,
and MENU.
The EVIC module contains a central processing
unit and interfaces with other electronic modules in
the vehicle over the Programmable Communications
Interface (PCI) J1850 data bus circuit. The PCI data
bus circuit allows the sharing of sensor information.
This helps to reduce wire harness complexity, reduce
internal controller hardware, and reduce component
sensor current loads. At the same time, this system
provides increased reliability, enhanced diagnostics,
and allows the addition of many new feature capabil-
ities.
The EVIC ªMenuº push button provides the vehicle
operator with a user interface, which allows the
selection of several optional customer programmable
electronic features to suit individual preferences.
Refer toELECTRONIC VEHICLE INFORMA-
TION CENTER PROGRAMMINGin the Standard
Procedures section of this group for more information
on the customer programmable feature options.
If the vehicle is equipped with the optional univer-
sal transmitter transceiver, the EVIC will also dis-
play messages and an icon indicating when the
universal transmitter transceiver is being trained,
which of the three transmitter buttons is transmit-
ting, and when the transceiver is cleared.
Data input for all EVIC functions, including VFD
dimming level, is received through the J1850 PCI
data bus circuit. The EVIC module uses its internal
programming and all of its data inputs to calculate
and display the requested data. If the data displayed
is incorrect, perform the self-diagnostic tests as
described in this group. If these tests prove inconclu-
DEGAUSSING TOOL #6029
8M - 6 MESSAGE SYSTEMSRS
OVERHEAD CONSOLE (Continued)

LIFTGATE SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Liftgate opens unexpectedly Failure of Power Liftgate or Body
Control moduleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of latch assembly Check wiring connections and for blown
fuse
Check for trouble codes, replace latch if
necessary
Failure of open/close command
switchCheck for shorted or defective switch
Liftgate will not open from
outside of vehicle manuallyFailure of key cylinder assembly Check for broken key cylinder assembly
Check link rod connections at the latch and
key cylinder assembly
Check for binds or kinks in link rod
Check for foreign matter preventing the
operation of key cylinder assembly
Replace the necessary components
Failure of latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Replace latch assembly, if necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace necessary components
Liftgate will not open/close
under powerFailure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using Body Diagnostic
Manual Replace latch assembly, if
necessary
Failure of motor assembly Troubleshoot using Body Diagnostic
Manual
Failure of full open switch Troubleshoot using Body Diagnostic
Manual
RSPOWER LIFTGATE SYSTEM8N-5
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Binding or sticking of components Establish location of binding and replace
necessary components
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Power loss during Liftgate
operationWiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Low battery voltage Charge battery
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of motor assembly Check for no drive condition
No power latching in
primary and/or secondary
positionsFailure of latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using Body Diagnostic
Manual. Replace latch assembly, if
necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter or other possible obstruction
Failure of motor assembly Check for no drive condition
Latch will not fully release
from primary positionFailure of latch assembly Check wire connections and for blown fuse
Check for foreign matter or damaged
components preventing the operation of
latch assembly
Troubleshoot using body electrical
troubleshooting manual Replace latch
assembly, if necessary
Failure of outside handle switch Troubleshoot using Body Diagnostic
Manual Replace switch, if necessary
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Binding or sticking of components Establish location of binding and replace
necessary components
8N - 6 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Key fob, Outside Handle or
overhead console switches
do not power operate
liftgateBlown Fuse Check fuse and replace
Battery voltage low Charge or replace battery in key fob or
vehicle
Failure of latch assembly Check for foreign matter preventing the
operation of latch assembly
Check wire connection
Pawl and/or ratchet switch inoperative
Replace latch if necessary
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Failure of Body Control Module
(BCM)Check electrical connections
Refer to the Body electrical troubleshooting
guide for additional checks
Replace BCM if necessary
Failure of key fob Reprogram key fob
Replace key fob if necessary
Failure of Power Liftgate Module Disconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of liftgate motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections
Motor clutch does not engage, replace
assembly
Full open switch inoperative, replace
switch, if necessary
Troubleshoot using Body Diagnostic
Manual Replace motor, if necessary
Liftgate does not stay open Failure of liftgate prop rods Replace prop rods, if necessary
Check for broken attachments
High inside/outside opening
effortFailure of liftgate prop rods Replace prop rods, if necessary
Check for broken attachments
Gear motor did not disengage Troubleshoot using Body Diagnostic
Manual Replace components, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
RSPOWER LIFTGATE SYSTEM8N-7
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Liftgate continues to cinch
closed during power modeFailure of latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using Body Diagnostic
Manual Replace components, if necessary
Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Liftgate continues to open
during power mode
(runaway motor)Failure of Power Liftgate or Body
Control ModuleDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of full open switch Check wire connections
Replace switch, if necessary
Failure of motor assembly Check for continuous drive condition
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to Wiring Diagrams
Liftgate opens very slowly Failure of liftgate motor assembly Check wire connections
Replace motor assembly, if necessary
Failure of liftgate prop rods Replace prop rods, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Grade of vehicle too steep for power
operationOperate liftgate manually
Squeaks, Noises and rattles Foreign material in door
compartmentRemove foreign material
Loose components Check and tighten loose components
8N - 8 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)