2004 CHRYSLER VOYAGER Service Manual

remove seats fuel tank removal tires wheelbase drain bolt check engine light

Page 569 of 2585

CHRYSLER VOYAGER 2004 Service Manual DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER
Compass Mini-Trip Computer (CMTC) and Com-
pass Temperature (CT) data is obtained from the
Body Control Module (BCM) on the J1850 Data Bus
circuit. T

DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER
Compass Mini-Trip Computer (CMTC) and Com-
pass Temperature (CT) data is obtained from the
Body Control Module (BCM) on the J1850 Data Bus
circuit. The CMTC and CT will display dashes (- -)
for any of the screens it did not receive the bus mes-
sages. The label corresponding to the missing infor-
mation will be lit. If no compass mini-trip computer
data is displayed, check the J1850 Data Bus circuit
communications and the BCM. If the brightness level
is improper check the J1850 Data Bus circuit.
The DRB IIItis recommended for checking the
J1850 Data Bus circuit and the BCM. Perform the
CMTC, CT self diagnosis before replacing the CMTC
or CT module.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove overhead console(Refer to 8 - ELEC-
TRICAL/OVERHEAD CONSOLE - REMOVAL).
(3) Remove the screws holding Compass Mini-Trip
Computer module in the overhead console.
(4) Remove CMTC module from console assembly.
INSTALLATION
(1) Position the compass mini-trip computer mod-
ule in the overhead console.
(2) Install the ten screws holding the compass
mini-trip computer module in the overhead console.
(3) Install the overhead console (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - INSTALLA-
TION).
(4) Connect the battery negative cable.
NOTE: If a new EVIC module has been installed, the
compass will have to be calibrated and the variance
set. Refer to compass variation adjustment and
compass calibration in standard procedures.
UNIVERSAL TRANSMITTER
DESCRIPTION
On some RS models a Universal Transmitter trans-
ceiver is standard factory-installed equipment. The
universal transmitter transceiver is integral to the
Electronic Vehicle Information Center (EVIC) and the
Compass Mini-Trip Computer (CMTC) modules,
which is located in the overhead console. The only
visible component of the universal transmitter are
the three transmitter push buttons centered between
the modules push buttons located just rearward of
the display screen in the overhead console. The threeuniversal transmitter push buttons are identified
with one, two or three light indicators so that they be
easily identified by sight or by feel.
Each of the three universal transmitter push but-
tons controls an independent radio transmitter chan-
nel. Each of these three channels can be trained to
transmit a different radio frequency signal for the
remote operation of garage door openers, motorized
gate openers, home or office lighting, security sys-
tems or just about any other device that can be
equipped with a radio receiver in the 286 to 399
MegaHertz (MHz) frequency range for remote opera-
tion. The universal transmitter is capable of operat-
ing systems using either rolling code or non-rolling
code technology.
The electronics module displays messages and a
small house-shaped icon with one, two or three dots
corresponding to the three transmitter buttons to
indicate the status of the universal transmitter. The
EVIC messages are:
²Cleared Channels- Indicates that all of the
transmitter codes stored in the universal transmitter
have been successfully cleared.
²Training- Indicates that the universal trans-
mitter is in its transmitter learning mode.
²Trained- Indicates that the universal transmit-
ter has successfully acquired a new transmitter code.
²Transmit- Indicates that a trained universal
transmitter button has been depressed and that the
universal transmitter is transmitting.
The universal transmitter cannot be repaired, and
is available for service only as a unit with the EVIC
or CMTC modules. If any of these components is
faulty or damaged, the complete EVIC or CMTC
module must be replaced.
OPERATION
The universal transmitter operates on a non-
switched source of battery current so the unit will
remain functional, regardless of the ignition switch
position. For more information on the features, pro-
gramming procedures and operation of the universal
transmitter, see the owner's manual in the vehicle
glove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
If the Universal Transmitter is inoperative, but the
Electronic Vehicle Information Center (EVIC) is oper-
ating normally, see the owner's manual in the vehicle
glove box for instructions on training the Transmit-
ter. Retrain the Transmitter with a known good
transmitter as instructed in the owner's manual and
test the Transmitter operation again. If the unit is
still inoperative, test the universal transmitter with
Radio Frequency Detector special tool. If both the
8M - 10 MESSAGE SYSTEMSRS
COMPASS/MINI-TRIP COMPUTER (Continued)

Page 570 of 2585

CHRYSLER VOYAGER 2004 Service Manual Transmitter and the EVIC module are inoperative,
refer toElectronic Vehicle Information Center
Diagnosis and Testingin this group for further
diagnosis. For complete circuit diagrams, refer to
Wiring

Transmitter and the EVIC module are inoperative,
refer toElectronic Vehicle Information Center
Diagnosis and Testingin this group for further
diagnosis. For complete circuit diagrams, refer to
Wiring Diagrams. (Fig. 5) as described below:
(1) Turn the Radio Frequency (RF) Detector ON. A
ªchirpº will sound and the green power LED will
light. If the green LED does not light, replace the
battery.
(2) Hold the RF detector within one inch of the
TRAINED universal transmitter and press any of the
transmitters buttons.
(3) The red signal detection LEDs will light and
the tool will beep if a radio signal is detected. Repeat
this test three times.
STANDARD PROCEDURE
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES
(1) Turn off the engine.
(2) Erase the codes by pressing the two outside
buttons. Release the buttons when the display con-
firms the operation (about 20 seconds).
(3) Choose one of the three buttons to train. Place
the hand-held transmitter within one inch of the uni-
versal transmitter and push the buttons on both
transmitters.(4) Release both buttons. Your universal transmit-
ter is now ªtrainedº. To train the other buttons,
repeat Step 3 and Step 4. Be sure to keep your hand-
held transmitter in case you need to retrain the uni-
versal transmitter.
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES
To erase the universal transmitter codes, simply
hold down the two outside buttons until the display
confirms the operation.
NOTE: Individual channels cannot be erased. Eras-
ing the transmitter codes will erase ALL pro-
grammed codes.
REMOVAL
(1) For universal transmitter removal and installa-
tion procedure, (Refer to 8 - ELECTRICAL/OVER-
HEAD CONSOLE/COMPASS/MINI-TRIP
COMPUTER - REMOVAL and INSTALLATION).
AMBIENT TEMP SENSOR
DESCRIPTION
Ambient air temperature is monitored by the over-
head console through ambient temperature messages
received from the Front Control Module (FCM) over
the Programmable Communications Interface (PCI)
J1850 data bus circuit. The FCM receives a hard
wired input from the ambient temperature sensor.
The ambient temperature sensor is a variable resis-
tor mounted to a bracket that is secured with a screw
to the right side of the headlamp mounting module
grille opening, behind the radiator grille and in front
of the engine compartment.
For more information on the Front Control Module
refer to the Electronic Control Modules section of this
manual. For complete circuit diagrams, refer to the
appropriate wiring information. The ambient temper-
ature sensor cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the Front Control Module. The resis-
tance in the sensor changes as temperature changes,
changing the temperature sensor signal circuit volt-
age to the Front Control Module. Based upon the
resistance in the sensor, the Front Control Module
senses a specific voltage on the temperature sensor
signal circuit, which it is programmed to correspond
to a specific temperature. The Front Control Module
Fig. 5 RADIO FREQUENCY DETECTOR
1 - SIGNAL DETECTION LED'S
2 - POWER LED
3 - ON/OFF SWITCH
4 - 9V BATTERY
RSMESSAGE SYSTEMS8M-11
UNIVERSAL TRANSMITTER (Continued)

Page 571 of 2585

CHRYSLER VOYAGER 2004 Service Manual then sends the proper ambient temperature mes-
sages to the EVIC, CMTC over the PCI J1850 data
bus.
The thermometer function is supported by the
ambient temperature sensor, a wiring circuit, the
Front

then sends the proper ambient temperature mes-
sages to the EVIC, CMTC over the PCI J1850 data
bus.
The thermometer function is supported by the
ambient temperature sensor, a wiring circuit, the
Front Control Module, the Programmable Communi-
cations Interface (PCI) data bus, and a portion of the
Electronics module. If any portion of the ambient
temperature sensor circuit fails, the Front Control
Module will self-diagnose the circuit.
The ambient temperature sensor circuit can also be
diagnosed by referring toDiagnosis and Testing -
Ambient Temperature Sensor, and Diagnosis
and Testing - Ambient Temperature Sensor Cir-
cuit. If the temperature sensor and circuit are con-
firmed to be OK, but the temperature display is
inoperative or incorrect, refer toDiagnosis and
Testing - Overhead Consolein this group. For
complete circuit diagrams, refer to the appropriate
wiring information.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector.
(2) Measure the resistance of the ambient temper-
ature sensor. At ±40É C (±40É F), the sensor resis-
tance is 336.6 kilohms. At 60É C (140É F), the sensor
resistance is 2.49 kilohms. The sensor resistance
should read between these two values. If OK, refer to
Diagnosis and Testing - Ambient Temperature
Sensor Circuitin this group. If not OK, replace the
faulty ambient temperature sensor.
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR CIRCUIT
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector and the Front Control Module wire
harness connector.(2) Connect a jumper wire between the two termi-
nals in the body half of the ambient temperature sen-
sor wire harness connector.
(3) Check for continuity between the sensor return
circuit and the ambient temperature sensor signal
circuit cavities of the Front Control Module wire har-
ness connector. There should be continuity. If OK, go
to Step 4. If not OK, repair the open sensor return
circuit or ambient temperature sensor signal circuit
to the ambient temperature sensor as required.
(4) Remove the jumper wire from the body half of
the ambient temperature sensor wire harness con-
nector. Check for continuity between the sensor
return circuit cavity of the Front Control Module
wire harness connector and a good ground. There
should be no continuity. If OK, go to Step 5. If not
OK, repair the shorted sensor return circuit as
required.
(5) Check for continuity between the ambient tem-
perature sensor signal circuit cavity of the Front
Control Module wire harness connector and a good
ground. There should be no continuity. If OK, refer to
Diagnosis and Testing - Overhead Consolein
this group. If not OK, repair the shorted ambient
temperature sensor signal circuit as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind front bumper fascia, remove
screw holding sensor to radiator closure panel.
(3) Disconnect the sensor electrical connector.
Depress the connector retaining tab and pull the con-
nector straight off the ambient temperature sensor.
(4) Remove sensor from vehicle.
INSTALLATION
(1) Position the sensor in the vehicle and connect
the sensor electrical connector.
(2) From behind the front bumper fascia, install
the screw holding sensor to radiator closure panel.
(3) Connect the battery negative cable.
8M - 12 MESSAGE SYSTEMSRS
AMBIENT TEMP SENSOR (Continued)

Page 572 of 2585

CHRYSLER VOYAGER 2004 Service Manual POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM.................. 1
POWER SLIDING DOOR SYSTEM............ 19
POWER LOCKS........................... 38POWER MIRRORS.....................

POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM.................. 1
POWER SLIDING DOOR SYSTEM............ 19
POWER LOCKS........................... 38POWER MIRRORS........................ 45
POWER SEAT SYSTEM..................... 50
POWER WINDOWS........................ 62
POWER LIFTGATE SYSTEM
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM
DESCRIPTION..........................2
OPERATION............................3
DIAGNOSIS AND TESTING - POWER
LIFTGATE SYSTEM.....................4
STANDARD PROCEDURE
STANDARD PROCEDURE - LIFTGATE
ADJUSTMENT.........................9
STANDARD PROCEDURE - POWER
LIFTGATE LEARN CYCLE................9
SPECIFICATIONS
SPECIFICATIONS TABLE................9
CHIME/THERMISTOR
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................10
ENGAGE ACTUATOR
DESCRIPTION.........................10
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11
EXTERIOR HANDLE SWITCH
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................12
FULL OPEN SWITCH
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................13INSTALLATION.........................13
LATCH
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................14
LATCH ACTUATOR
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................14
INSTALLATION.........................14
LIFTGATE MOTOR
DESCRIPTION.........................15
OPERATION...........................15
REMOVAL.............................15
INSTALLATION.........................15
LIFT GEAR & LINK ROD
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
PINCH SENSOR
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................17
TRANSVERSE BRACKET
DESCRIPTION.........................18
OPERATION...........................18
REMOVAL.............................18
INSTALLATION.........................18
RSPOWER SYSTEMS8N-1

Page 573 of 2585

CHRYSLER VOYAGER 2004 Service Manual POWER LIFTGATE SYSTEM
DESCRIPTION
Some vehicles are equipped with an automatic
opening and closing power liftgate system (Fig. 1).
This power liftgate system is a complex system con-
sisting of many c

POWER LIFTGATE SYSTEM
DESCRIPTION
Some vehicles are equipped with an automatic
opening and closing power liftgate system (Fig. 1).
This power liftgate system is a complex system con-
sisting of many components. Some of these compo-
nents are the liftgate gear motor assembly, latch
assembly, lift gear and rod, liftgate control module,
chime/thermistor, full open switch, engage actuator,
pinch sensor, liftgate handle switch, overhead console
switch, key fob switches (Fig. 2), pawl switch and
ratchet switch.
The power liftgate system has its own door control
module, located on the vehicles left body D-pillar
behind the trim panel. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/DOOR CON-
TROL MODULE - DESCRIPTION) The power
liftgate gear motor assembly is located just above the
control module. The latch assembly is located in the
bottom center of the power liftgate, below the exte-
rior liftgate handle switch. The power liftgate full
open switch, engage actuator, lift gear and rod are
part of the liftgate gear motor assembly. The pawl
and ratchet switches are part of the latch assembly.
The pinch sensor or sensors are located along theright and left sides of the power liftgate, just above
the body line. The liftgate handle switch is an power
release switch and is located in the rear light bar
assembly, just above the license plate. The overhead
console switch is an power open and close command
switch located in the vehicles overhead console.
Safety is of the utmost concern with the power lift-
gate system. Software technology has enabled the
power liftgate control module to detect resistance to
liftgate travel, which allows the power liftgate to stop
and reverse direction anytime an obstruction is felt
or any of the command switches are operated (only in
closing direction). Battery voltage is supplied to the
power liftgate system through a 40 amp fuse, located
in the Intelligent Power Module (IPM) assembly (Fig.
3). In the unlikely event that the power liftgate sys-
tem develops a fault the power liftgate can still be
operated manually with a key, just like a standard
manual liftgate.
The power liftgate control module communicates
on the J1850 Programmable Communication Inter-
face (PCI) Bus Circuit. Therefore, the power liftgate
control module can generate and store its own Diag-
nostic Trouble Codes (DTC). The vehicles Body Con-
trol Module (BCM) receives and supplies messages to
the power liftgate control module via the PCI bus cir-
cuit. A diagnostic scan tool, such as the DRB IIItis
Fig. 1 POWER LIFTGATE INTRODUCTION
8N - 2 POWER LIFTGATE SYSTEMRS

Page 574 of 2585

CHRYSLER VOYAGER 2004 Service Manual used to read and troubleshoot these Diagnostic Trou-
ble Codes (DTC). Refer to the Body Diagnostic Man-
ual for a complete list of diagnostic routines.
For additional information refer to Power Liftga

used to read and troubleshoot these Diagnostic Trou-
ble Codes (DTC). Refer to the Body Diagnostic Man-
ual for a complete list of diagnostic routines.
For additional information refer to Power Liftgate
Operation. For a complete system wiring schematic
refer to Wiring Diagrams. For system operationinstructions refer to the vehicles owner manual.
Refer to the Body section of the service manual
for additional information on liftgate components
such as the prop rods, hinges, door alignment and
striker alignment.
WARNING: BE CERTAIN TO READ ALL WARNINGS
AND CAUTIONS (NOTED BELOW) IN POWER LIFT-
GATE SYSTEM OPERATION BEFORE ATTEMPTING
ANY SERVICE OF THE POWER LIFTGATE SYSTEM
OR COMPONENTS.
OPERATION
With the push of a power liftgate open/close com-
mand switch (key fob or overhead console mounted) a
signal is sent out on the J1850 PCI Data Bus circuit.
This signal is detected at the body control module
(BCM). The BCM then sends a signal out on the
J1850 PCI Data Bus circuit to the power liftgate
module. The power liftgate module then signals the
power liftgate motor to start an open or close cycle,
depending on what position the liftgate is in open or
closed.
During a liftgate open or close cycle, if the power
liftgate module detects sufficient resistance to liftgate
travel, such as an obstruction in the liftgates path,
the power liftgate control module will immediately
stop the liftgate movement and reverse travel to the
full open or closed position. The ability for the power
liftgate module to detect resistance to liftgate travel
is accomplished by hall effect sensors, drive motor
speed and pinch sensors (tape switches).
The power liftgate control module has the ability to
learn. Anytime the liftgate is opened or closed using
the power liftgate system the module learns from its
cycle. If a replacement power liftgate component is
installed or a liftgate adjustment is made, the mod-
ule will relearn the effort and/or time required to
open or close the door. This learn cycle can be per-
formed with a Diagnostic Scan Tool, such as the
DRB IIItor with a complete cycle of the liftgate,
using any one of the command switches. Refer to
Standard Procedures in this section for detailed
instructions.
The power liftgate system is designed with a num-
ber of system inhibitors. These inhibitors are neces-
sary for safety and / or feasibility of the power
liftgate system. Refer to power liftgate system inhib-
itors noted below:
POWER LIFTGATE SYSTEM INHIBITORS
²The Power Liftgate may not operate in extreme
temperatures. These extreme temperatures will be
approximately -12É F (-24.4É C) on the low side and
143É F (61.6É C) for the high side. A chime/thermister
Fig. 2 KEY FOB
1 - Left Sliding Door Switch
2 - Right Sliding Door Switch
3 - Liftgate Switch
Fig. 3 LIFTGATE FUSE LOCATION
RSPOWER LIFTGATE SYSTEM8N-3
POWER LIFTGATE SYSTEM (Continued)

Page 575 of 2585

CHRYSLER VOYAGER 2004 Service Manual assembly in the rear light bar assembly monitors the
outside temperature.
²The vehicle transmission must be in Park or
Neutral for the power liftgate to start a cycle.
²If multiple obstacles are det

assembly in the rear light bar assembly monitors the
outside temperature.
²The vehicle transmission must be in Park or
Neutral for the power liftgate to start a cycle.
²If multiple obstacles are detected during the
same power open or close cycle, the liftgate goes into
manual operation.
²If severe problems occur, Diagnostic Trouble
Codes (DTC) are stored in the power liftgate control
module.
POWER LIFTGATE SYSTEM CAUTIONS AND
WARNINGS
WARNING: ALWAYS DISCONNECT THE NEGATIVE
BATTERY CABLE BEFORE ATTEMPTING ANY
POWER LIFTGATE SYSTEM SERVICE.
WARNING: THERE IS A SMALL AREA ON BOTH
SIDES OF THE LOWER POWER LIFTGATE WHICH
ARE NOT PROTECTED BY PINCH SENSORS.
EXTREME CARE MUST BE TAKEN TO PREVENT
OBJECTS FROM ENTERING THIS AREA ONCE THE
LIFTGATE REACHES THE SECONDARY LATCH
CONTACT (APPROXIMATELY 1/2 INCH BEFORE
FULLY CLOSED).
WARNING: NEVER ATTEMPT TO ENTER OR EXIT
THE VEHICLE WITH THE LIFTGATE IN MOTION.
YOU COULD DAMAGE THE POWER LIFTGATE SYS-
TEM AND/OR COMPONENTS AND/OR CAUSE PER-
SONAL INJURY.
WARNING: NEVER STICK OBJECTS IN THE POWER
LIFTGATE WHEN CINCHING CLOSED. YOU COULDDAMAGE THE VEHICLE, POWER LIFTGATE SYS-
TEM COMPONENTS AND/OR CAUSE PERSONAL
INJURY.
DIAGNOSIS AND TESTING - POWER LIFTGATE
SYSTEM
The power opening and closing power liftgate sys-
tem is a complex system containing many compo-
nents and modules. In order to obtain conclusive
testing the Programmable Communications Interface
(J1850) data bus network and all of the electronic
modules that provide inputs to, or receive outputs
from the power liftgate system must be checked.
The power liftgate system was designed to be diag-
nosed with an appropriate diagnostic scan tool, such
as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the power liftgate system
requires the use of a DRB IIItscan tool and the
proper Body Diagnostic Procedures manual. The
DRB IIItcan be used to observe various switch sta-
tuses throughout the power liftgate system to help
the technician diagnose a defective switch or compo-
nent. The DRB IIItcan also be used to actuate var-
ious components throughout the power liftgate
system to help the technician diagnose a defective
component.
Before any testing of the power liftgate system is
attempted, the battery should be fully charged, all
built-in power liftgate system inhibitors read and
understood (Refer to power liftgate system operation)
and all wire harness and ground connections
inspected around the affected areas on the vehicle.
Following are quick reference diagnostic tables to
help when diagnosing and testing the power liftgate
system.
8N - 4 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

Page 576 of 2585

CHRYSLER VOYAGER 2004 Service Manual 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 l

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