2004 CHRYSLER VOYAGER Vacuum

Component Page
Left Visor/Vanity Lamp (Premium/Luxury Except
Export)......................... 8W-80-96
License Lamp (Manual Release)........ 8W-80-96
License Lamp (Power Liftgate)......... 8W-80-96
License Lamp (Power Release)......... 8W-80-97
Lift Pump Motor (Diesel)............. 8W-80-97
Liftgate Ajar Switch (Manual Release) . . . 8W-80-97
Liftgate Ajar Switch (Power Release).... 8W-80-97
Liftgate Cinch/Release Motor (Power
Liftgate)........................ 8W-80-98
Liftgate Left Pinch Sensor (Power
Liftgate)........................ 8W-80-98
Liftgate Right Pinch Sensor (Power
Liftgate)........................ 8W-80-98
Low Note Horn..................... 8W-80-98
Manifold ABSolute Pressure Sensor
(Gas)........................... 8W-80-98
Mass Air Flow Sensor (Diesel)......... 8W-80-99
Memory Seat Switch................. 8W-80-99
Memory Seat/Mirror Module C1....... 8W-80-100
Memory Seat/Mirror Module C2....... 8W-80-100
Memory Seat/Mirror Module C3....... 8W-80-100
Memory Seat/Mirror Module C4....... 8W-80-101
Message Center (Highline)........... 8W-80-101
Mode Door Actuator................ 8W-80-101
Multi-Function Switch.............. 8W-80-101
Natural Vacuum Leak Detection Assembly (Except
Export)........................ 8W-80-102
Output Speed Sensor............... 8W-80-102
Overhead Console (Except Base)...... 8W-80-102
Oxygen Sensor 1/1 Upstream (Gas).... 8W-80-102
Oxygen Sensor 1/2 Downstream (Gas) . . 8W-80-103
Passenger Airbag.................. 8W-80-103
Passenger Blend Door Actuator....... 8W-80-103
Passenger Door Courtesy Lamp....... 8W-80-103
Passenger Door Lock Switch.......... 8W-80-103
Passenger Folding Mirror Relay
(Export)....................... 8W-80-104
Passenger Heated Seat Back......... 8W-80-104
Passenger Heated Seat Cushion....... 8W-80-104
Passenger Heated Seat Module C1..... 8W-80-104
Passenger Heated Seat Module C2..... 8W-80-105
Passenger Heated Seat Module C3..... 8W-80-105
Passenger Power Seat Front Riser
Motor......................... 8W-80-105
Passenger Power Seat Horizontal Motor . 8W-80-105
Passenger Power Seat Rear Riser
Motor......................... 8W-80-106
Passenger Power Seat Recliner Motor . . 8W-80-106
Passenger Power Seat Switch......... 8W-80-106
Passenger Power Window Motor....... 8W-80-106
Passenger Power Window Switch...... 8W-80-107
Passenger Seat Belt Switch.......... 8W-80-107
Passenger Seat Belt Tensioner........ 8W-80-107
Power Folding Mirror Switch (Export) . . 8W-80-107Component Page
Power Liftgate Module C1........... 8W-80-108
Power Liftgate Module C2........... 8W-80-108
Power Liftgate Motor............... 8W-80-108
Power Mirror Switch............... 8W-80-109
Power Outlet (Except Lowline)........ 8W-80-109
Power Seat Circuit Breaker (30A)..... 8W-80-109
Power Window Circuit Breaker (25A) . . . 8W-80-109
Power Window Switch (LHD Lowline) . . 8W-80-110
Powertrain Control Module C1........ 8W-80-110
Powertrain Control Module C2........ 8W-80-111
Powertrain Control Module C3........ 8W-80-112
Powertrain Control Module C4........ 8W-80-113
Radiator Fan No. 1 (Diesel).......... 8W-80-114
Radiator Fan No. 1 (Gas)............ 8W-80-114
Radiator Fan No. 2 (Diesel).......... 8W-80-114
Radiator Fan No. 2 (Gas)............ 8W-80-114
Radiator Fan Relay (Gas)............ 8W-80-115
Radiator Fan Relay No. 1 (Diesel)..... 8W-80-115
Radiator Fan Relay No. 2 (Diesel)..... 8W-80-115
Radiator Fan Relay No. 3 (Diesel)..... 8W-80-115
Radio C1......................... 8W-80-116
Radio C2 (CD Changer)............. 8W-80-116
Radio C2 (DVD/CD Changer)......... 8W-80-117
Rear A/C-Heater Unit (3 Zone MTC).... 8W-80-117
Rear Auto Temp Control Switch (3 Zone
ATC) .......................... 8W-80-117
Rear Blower Front Control Switch (3 Zone
MTC)......................... 8W-80-118
Rear Blower Motor Power Module C1 (3 Zone
ATC) .......................... 8W-80-118
Rear Blower Motor Power Module C2 (3 Zone
ATC) .......................... 8W-80-118
Rear Blower Rear Control Switch C1 (3 Zone
MTC)......................... 8W-80-118
Rear Blower Rear Control Switch C2 (3 Zone
MTC)......................... 8W-80-119
Rear Dome Lamp (Except Luxury)..... 8W-80-119
Rear Intrusion Sensor (United
Kingdom)...................... 8W-80-119
Rear Mode Motor (3 Zone ATC)........ 8W-80-119
Rear Power Outlet................. 8W-80-119
Rear Temperature Motor (3 Zone ATC) . . 8W-80-120
Rear Wiper Motor.................. 8W-80-120
Recirculation Door Actuator.......... 8W-80-120
Remote Keyless Entry Antenna (Japan) . 8W-80-120
Right B-Pillar Switch (Power Sliding
Door).......................... 8W-80-120
Right Cinch/Release Motor (Power Sliding
Door).......................... 8W-80-121
Right Cylinder Lock Switch (Export) . . . 8W-80-121
Right Door Speaker (Highline)........ 8W-80-121
Right Door Speaker (Lowline)......... 8W-80-121
Right Fog Lamp (Except Export)...... 8W-80-122
Right Fog Lamp (Export)............ 8W-80-122
Right Front Door Ajar Switch (Base) . . . 8W-80-122
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTSRS

NATURAL VACUUM LEAK DETECTION ASSEMBLY (EXCEPT EXPORT) - LT. GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z166 18BK/WT GROUND
2 K107 18VT/WT NVLD SWITCH SIGNAL
3 K106 18VT/LB NVLD SOL CONTROL
OUTPUT SPEED SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 T13 18DG/VT SPEED SENSOR GROUND
2 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 G23 22VT/DB SLIDING DOORS OVERHEAD SWITCH MUX
2 G25 22VT/TN LIFTGATE SWITCH MUX
3 D25 20WT/VT PCI BUS
4 Z113 20BK/DB GROUND
5 A114 20GY/RD FUSED B(+) (I.O.D.)
6 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
7 Z13 20BK/WT GROUND
8 E15 20OR/DB ASH/RECEIVER LAMP FEED
9- -
10 - -
11 L24 20BK/GY (EXCEPT EXPORT/PRE-
MIUM/LUXURY)AUTOMATIC HEADLAMP SWITCH SENSOR
12 L1 20BK/WT (PREMIUM/LUXURY) BACK-UP LAMP FEED
OXYGEN SENSOR 1/1 UPSTREAM (GAS)-4WAY
CAV CIRCUIT FUNCTION
1 Z42 18BK/LG GROUND
2 K99 18BR/LG O2 1/1 HEATER CONTROL
3 K902 18BR/DG O2 RETURN (UP)
4 K41 18DB/LB O2 1/1 SIGNAL
8W - 80 - 102 8W-80 CONNECTOR PIN-OUTSRS

POWERTRAIN CONTROL MODULE C3 - BLACK 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 K51 18BR/WT ASD RELAY CONTROL
4- -
5 V35 18VT/OR S/C VENT CONTROL
6 K173 18BR/VT CONDENSER FAN RELAY CONTROL
7 V32 18VT/YL SPEED CONTROL SUPPLY
8 K106 20VT/LB (EXCEPT EXPORT) NVLD SOL CONTROL
9 K299 18BR/WT O2 1/2 HEATER CONTROL
10 - -
11 C13 18LB/OR A/C CLUTCH RELAY CONTROL
12 V36 18VT/YL S/C VACUUM CONTROL
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 K342 16BR/WT ASD RELAY OUTPUT
20 K52 18DB/WT EVAP PURGE CONTROL
21 T141 18YL (MTX EXPORT) FUSED IGNITION SWITCH OUTPUT (START)
22 - -
23 B29 18DG/WT BRAKE SWITCH SIGNAL
24 - -
25 - -
26 - -
27 - -
28 K342 16BR/WT ASD RELAY OUTPUT
29 K70 18DB/BR EVAP PURGE SIGNAL
30 - -
31 C18 18LB/BR A/C PRESSURE SIGNAL
32 K91 18DB/YL BATTERY TEMP SIGNAL
33 - -
34 V37 18VT S/C SWITCH NO. 1 SIGNAL
35 K107 20VT/WT (EXCEPT EXPORT) NVLD SWITCH SIGNAL
36 - -
37 K31 18BR FUEL PUMP RELAY CONTROL
38 T752 18DG/OR STARTER RELAY CONTROL
8W - 80 - 112 8W-80 CONNECTOR PIN-OUTSRS

RIGHT VISOR/VANITY LAMP (PREMIUM/LUXURY EXCEPT EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMPS DRIVER
SENTRY KEY REMOTE ENTRY MODULE (SKREEM) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 D10 18WT (RHD) REMOTE KEYLESS ENTRY ANTENNA (+)
2 D25 20WT/VT PCI BUS
3 D10 18WT/LB (RHD) REMOTE KEYLESS ENTRY ANTENNA (-)
4 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z120 22BK/WT GROUND
6 A114 20GY/RD FUSED B(+) (I.O.D.)
SIREN (UNITED KINGDOM) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 D96 18WT/LB SIREN SIGNAL CONTROL
3 A114 18GY/RD FUSED B(+) (I.O.D.)
4 Z109 18BK/GY GROUND
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18VT/YL S/C VACUUM CONTROL
2 V35 18VT/OR S/C VENT CONTROL
3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT
4 Z155 18BK/LG GROUND
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 131

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Liftgate Right Pinch Sensor
(Power Liftgate)BK Right Side of Liftgate 49
Low Note Horn BK Left Frame Rail 5
Manifold Absolute Pressure
Sensor (Gas)BK On Intake N/S
Mass Air Flow Sensor (Diesel) OR Top of Engine 15, 16
Memory Seat/Mirror Module C1 GY Under Driver Seat N/S
Memory Seat/Mirror Module C2 GY Under Driver Seat N/S
Memory Seat/Mirror Module C3 WT Under Driver Seat N/S
Memory Seat/Mirror Module C4 GY Under Driver Seat N/S
Memory Seat Front Vertical Motor RD Under Seat N/S
Memory Seat Front Vertical
Position SensorBK Under Seat N/S
Memory Seat Horizontal Motor BK Under Seat N/S
Memory Seat Horizontal Position
SensorBK Under Seat N/S
Memory Seat Rear Vertical Motor RD Under Seat N/S
Memory Seat Rear Vertical
Position SensorBK Under Seat N/S
Memory Seat Recliner Motor GN Under Seat N/S
Memory Seat Recliner Position
SensorBK Under Seat N/S
Memory Set Switch BK At Switch Driver Door 43
Message Center (Highline) WT Rear of Message Center 20, 21, 28
Mode Door Actuator GY Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 20, 21, 22, 23, 31
Natural Vacuum Leak Detection
Assembly (Except Export)LTGY Top of Engine 12
Output Speed Sensor GY Front of Transmission 14, 18, 19
Overhead Console (Except Base) BK Front of Console N/S
Oxygen Sensor 1/1 Upstream
(Gas)BK Rear of Engine 11, 12, 18
Oxygen Sensor 1/2 Downstream
(Gas)BK Rear of Engine 11, 12,18
Passenger Airbag YL Passenger Side of Instrument Panel 20, 23, 24 29
Passenger Blend Door Actuator GY On HVAC N/S
Passenger Door Courtesy Lamp GY At Lamp 44
Passenger Door Lock Switch BK At Switch 44
Passenger Folding Mirror Relay
(Export)BL Left Kick Panel 7
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module
C1GY At Heated Seat N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect battery negative cable.
(3) Remove air cleaner housing and inlet tube.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- STANDARD PROCEDURE)
(5) Disconnect all vacuum hoses.
(6) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(7) Remove radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(8) Remove radiator upper and lower hoses.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the transaxle,
damage to the inner wall of the hose will occur. To
prevent prevent potential leakage, the cooler hoses
must be cut off flush at the transaxle fitting, and a
service cooler hose splice kit must be installed
upon reassembly.(9) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug cooler
lines and fittings to prevent debris from entering
transaxle or cooler circuit. A service splice kit will be
installed upon reassembly.
(10) Disconnect transmission shift linkage and
electrical connectors.
(11) Disconnect throttle body linkage.
(12) Disconnect engine wiring harness.
(13) Disconnect heater hoses from heater (Fig. 5).
(14) Discharge air conditioning system. (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE)
(15) Hoist vehicle and remove front wheels and
tires.
(16) Remove accessory drive belt splash shield.
(17) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
Fig. 5 HEATER HOSES - 2.4L
1 - HEATER HOSES TO HEATER 3 - HEATER HOSE TO ENGINE - SUPPLY AND RETURN
2 - BOLT - HEATER TUBE SUPPORT
RSENGINE 2.4L9-13
ENGINE 2.4L (Continued)

INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.
(13) Connect power steering supply line to pump
and remove pinch-off pliers.(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16 ENGINE 2.4LRS
ENGINE 2.4L (Continued)