2004 CHRYSLER VOYAGER coolant temperature

The PCM controls engine idle speed by adjusting
the position of the idle air control valve. The adjust-
ments are based on inputs the PCM receives. The
inputs are from the throttle position sensor, crank-
shaft position sensor, coolant temperature sensor,
MAP sensor, vehicle speed sensor and various switch
operations (brake, park/neutral, air conditioning).
When engine rpm is above idle speed, the IAC is
used for the following functions:
²Off-idle dashpot
²Deceleration air flow control²A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged so
that the engine rpm does not dip down when the
compressor engages)
Target Idle
Target idle is determined by the following inputs:
²Gear position
²ECT Sensor
²Battery voltage
²Ambient/Battery Temperature Sensor
²VSS
²TPS
²MAP Sensor
REMOVAL
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. If assembly of component is diffi-
cult, a light coat of engine oil may be applied to the
O-RINGS ONLY to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from idle air con-
trol valve (Fig. 17).
(3) Remove idle air control valve mounting screw.
(4) Remove valve from throttle body. Ensure the
O-rings is removed with the valve.
INSTALLATION
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. If assembly of component is diffi-
cult,a light coat of engine oil may be applied to
Fig. 15 TPS/IAC 2.4L
1 - Idle Air Control Valve
2 - Throttle Position Sensor
Fig. 16 TPS/IAC 3.3/3.8L
1 - Idle Air Control Valve
2 - Throttle Position Sensor
Fig. 17 IDLE AIR CONTROL VALVE LOCATION
RSFUEL INJECTION14-29
IDLE AIR CONTROL MOTOR (Continued)

REMOVAL - 2.5L TD
(1) Raise hood.
(2) Disconnect both battery cables.
(3) Remove battery thermal shield (Fig. 15).
(4) Remove battery hold down bolt, clamp, and
battery (Fig. 16).(5) Remove battery tray (Fig. 17). Disconnect bat-
tery temperature sensor.
(6) Remove coolant recovery bottle from bracket.
(7) Remove coolant recovery bottle mounting
bracket (Fig. 18).
(8) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 19).
(9) Remove gearshift cable retaining clips from
mounting bracket (Fig. 19). Remove cables and
secure out of way.
Fig. 15 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 16 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 17 Battery Tray
1 - BATTERY TRAY
Fig. 18 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21-33
T850 MANUAL TRANSAXLE (Continued)

(15) Install coolant recovery bottle bracket (Fig.
88).
(16) Install coolant recovery bottle to bracket.
(17) Connect battery temperature sensor and
install battery tray (Fig. 89).(18) Install battery, hold-down clamp and nut (Fig.
90).
(19) Install battery thermal shield and clutch cable
eyelet (Fig. 91).
(20) Connect battery cables.
(21) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
Fig. 88 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 89 Battery Tray
1 - BATTERY TRAY
Fig. 90 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 91 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
RST850 MANUAL TRANSAXLE21-55
T850 MANUAL TRANSAXLE (Continued)

(10)2.4L Gas equipped models goto Step 15.
2.5L TD models:Remove battery thermal shield
(Fig. 138).
(11) Remove battery hold down nut, clamp, and
battery (Fig. 139).(12) Remove battery tray (Fig. 140). Disconnect
battery temperature sensor.
(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 141).
Fig. 138 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 139 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 140 Battery Tray
1 - BATTERY TRAY
Fig. 141 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21-75
GEARSHIFT CABLE - CROSSOVER (Continued)

(6) Install coolant recovery bottle to bracket.
(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 145).
(8) Install battery, hold-down clamp, and nut (Fig.
146).(9) Install battery thermal shield (Fig. 147).
(10) Install crossover cable to gearshift mechanism
(Fig. 148). Install retainer clip (Fig. 149).
Fig. 145 Battery Tray
1 - BATTERY TRAY
Fig. 146 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 147 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 148 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
RST850 MANUAL TRANSAXLE21-77
GEARSHIFT CABLE - CROSSOVER (Continued)

(11) Remove battery hold down nut, clamp, and
battery (Fig. 168).
(12) Remove battery tray (Fig. 169). Disconnect
battery temperature sensor.(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 170).
(15) Disconnect crossover cable from transaxle
crossover lever (Fig. 171).
(16) Remove crossover cable retainer clip and dis-
engage cable from mount bracket (Fig. 171).
Fig. 168 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 169 Battery Tray
1 - BATTERY TRAY
Fig. 170 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 171 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21-83
GEARSHIFT CABLE - SELECTOR (Continued)

(17) Raise vehicle on hoist.
(18) Remove selector cable from engine compart-
ment, then remove cable from passenger compart-
ment through opening in floor pan.
INSTALLATION
(1) From underneath vehicle, install gearshift
selector cable into passenger compartment through
floor pan hole. Install remainder of cable into posi-
tion in engine compartment.
(2) Lower vehicle.
(3) Install selector cable to mount bracket and
secure with retainer clip (Fig. 172).
(4) Install cable to transaxle selector lever (Fig.
172).
(5)2.4L Gas models goto Step 10. 2.5L TD
models:Install coolant recovery bottle bracket (Fig.
173).(6) Install coolant recovery bottle to bracket.
(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 174).
Fig. 172 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 173 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 174 Battery Tray
1 - BATTERY TRAY
21 - 84 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)

TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine's piston to the front
cover's friction material, a total converter engage-
ment can be obtained. The result of this engagement
is a direct 1:1 mechanical link between the engine
and the transmission.
The engagement and disengagement of the TCC
are automatic and controlled by the Powertrain Con-
trol Module (PCM). The engagement cannot be acti-
vated in the lower gears because it eliminates the
torque multiplication effect of the torque converter
necessary for acceleration. Inputs that determine
clutch engagement are: coolant temperature, vehicle
speed and throttle position. The torque converter
clutch is engaged by the clutch solenoid on the valve
body. The clutch will engage at approximately 56
km/h (35 mph) with light throttle, after the shift to
third gear.
REMOVAL
(1) Remove transmission and torque converter
from vehicle. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE - REMOVAL)
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 326). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE - INSTALLATION)
(9) Fill the transmission with the recommended
fluid. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 41TE/FLUID - STANDARD PROCE-
DURE)TRANSMISSION CONTROL
RELAY
DESCRIPTION
The transmission control relay (Fig. 327) is located
in the Intelligent Power Module (IPM), which is
located on the left side of the engine compartment
between the battery and left fender.
Fig. 326 Checking Torque Converter Seating
1 - SCALE
2 - STRAIGHTEDGE
RS41TE AUTOMATIC TRANSAXLE21 - 247
TORQUE CONVERTER (Continued)