2004 CHRYSLER VOYAGER sensor

(11) Remove the 3 mounting bolts.
(12) Lower vehicle.
(13) Remove oil dip stick tube from vehicle.
(14) Roll and remove the generator from vehicle
(Fig. 10).
INSTALLATION
INSTALLATION - 2.4L
(1) Install the generator.
(2) Install the accessory drive belt, refer to the
Cooling System section for proper procedures. (3) Connect B+ terminal to generator.
(4) Install nut holding B+ wire terminal to back of
generator. (5) Connect the push-in field wire connector to
back of generator. (6) Install the EVAP Purge solenoid to its bracket.
(7) Install the Air Box, refer to the Engine/Air
Cleaner for more information. (8) Connect the Inlet Air Temperature sensor.
(9) Connect battery negative cable.
INSTALLATION - 2.5L
(1) Install generator.
(2) Install the 2 lower mounting Bolts (Fig. 8).
(3) Install the Air Cleaner Box (Fig. 7).
(4) Install the upper support bracket (Fig. 6).
(5) Install the wiring harness on upper generator
bracket (Fig. 6). (6) Connect the field connection (Fig. 5).
(7) Connect the generator battery connection (Fig.
5). (8) Raise vehicle and support.
(9) Install the generator drive belt (Fig. 4).
(10) Install the right front splash shield (Fig. 3).
(11) Lower vehicle.
(12) Install the engine cover (Fig. 2).
(13) Connect the negative battery cable (Fig. 1).
INSTALLATION - 3.3/3.8L
(1) Roll and place generator in position on vehicle
(Fig. 10). (2) Install upper bolts to hold generator in place.
(3) Lubricate the o-ring. Install oil dip stick tube.
(4) Install the upper oil dip stick tube bolt.
(5) Place B+ terminal in position on generator.
(6) Install nut to hold B+ wire terminal to back of
generator. (7) Connect the push-in field wire connector into
back of generator. (8) Raise vehicle and support.
(9) Install the lower mounting bolt and tighten.
(10) Install the lower oil dip stick tube bolt and
tighten (Fig. 9).
Fig. 9 DIP STICK LOWER BOLT
Fig. 10 GENERATOR 3.3/3.8L
8Fs - 26 CHARGINGRS
GENERATOR (Continued)

VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground. Voltage is regulated within the PCM on the NGC
vehicles, to control the strength of the rotor magnetic
field. The EVR circuitry monitors system line voltage
at the PDC and calculated battery temperature or
inlet air temperature sensor (refer to Inlet Air Tem-
perature Sensor, if equipped, for more information ).
It then determines a target charging voltage. If
sensed battery voltage is lower than the target volt-
age, the PCM feeds the field winding until sensed
battery voltage is at the target voltage. A circuit in
the PCM cycles the feed side of the generator field at
250 times per second (250Hz), but has the capability
to feed the field control wire 100% of the time (full
field) to achieve the target voltage. If the charging
rate cannot be monitored (limp-in), a duty cycle of
20% is used by the PCM in order to have some gen-
erator output. Also refer to Charging System Opera-
tion for additional information.
Fig. 15 DECOUPLER INSTALLATION (Litens)
RS CHARGING8Fs-29
GENERATOR DECOUPLER PULLEY (Continued)

the battery, if required. Refer to the Battery section
for more information.² Ignition Switch - Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections. ² Transmission Range Sensor or Park/Neu-
tral Switch - Visually inspect the transmission
range sensor for indications of physical damage and
loose or corroded wire harness connections. ² Starter Relay - Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections. ² Starter Motor - Visually inspect the starter
motor for indications of physical damage and loose or
corroded wire harness connections. ²
Starter Solenoid - Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections. ² Wiring - Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required. Check for loose or corroded wire harness
connections at main engine ground and remote jump
post. ² Power Distribution Center (PDC) - Visually
inspect the B+ connections at the PDC for physical
damage and loose or corroded harness connections.
STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS
TO ENGAGE. 1. BATTERY
DISCHARGED OR
FAULTY. 1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY, IF
REQUIRED.
2. STARTING CIRCUIT
WIRING FAULTY. 2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY
FAULTY. 3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
4. IGNITION SWITCH
FAULTY. 4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. PARK/NEUTRAL
POSITION SWITCH
(AUTO TRANS) FAULTY
OR MIS-ADJUSTED. 5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
SWITCH, IF NECESSARY.
6. CLUTCH INTERLOCK
SWITCH (MAN TRANS)
FAULTY. 6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
7. STARTER SOLENOID
FAULTY. 7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
STARTER ASSEMBLY, IF NECESSARY.
8. STARTER ASSEMBLY
FAULTY. 8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
9. FAULTY TEETH ON
RING GEAR. 9. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
10. PCM DOUBLE
START OVERRIDE
OUTPUT FAILURE. 10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY
BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT
AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE. 1. BATTERY
DISCHARGED OR
FAULTY.
1. REFER TO THE BATTERY SECTION FOR MORE
INFORMATION. CHARGE OR REPLACE BATTERY AS
NECESSARY.
RS
STARTING8Fs-31
STARTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION2. STARTING CIRCUIT
WIRING FAULTY. 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEMBLY
FAULTY. 3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND. 5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR. 6. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS. 1. BROKEN TEETH ON
STARTER RING GEAR.
1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEMBLY
FAULTY. 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE. 1. STARTER
IMPROPERLY
INSTALLED. 1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY. 2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY. 3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEMBLY
FAULTY. 4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR. 5. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST
The starter control circuit has:
²
Starter motor with integral solenoid
² Starter relay
² Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions ² Ignition switch
² Battery
² All related wiring and connections
² Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled. ²
To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED. THIS MAY RESULT IN
PERSONAL INJURY OR DEATH.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
8Fs - 32 STARTINGRS
STARTING (Continued)

(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3. (3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required. (4) The coil battery terminal (85) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position and
the clutch pedal is depressed (manual trans). Check
for battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position and the
clutch pedal is depressed (manual trans), and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 5. If not OK, check for
an open or short circuit to the ignition switch and
repair, if required. If the circuit to the ignition switch
is OK, see the Ignition Switch Test procedure in this
group. (5) The coil ground terminal (86) is connected to
the electromagnet in the relay. It is grounded by the
PCM if the conditions are right to start the car. For
automatic trans. cars the PCM must see Park Neu-
tral switch low and near zero engine speed (rpm).
For manual trans. cars the PCM only needs to see
near zero engine speed (rpm) and low clutch inter-
lock input and see near zero engine speed (rpm). To
diagnose the Park Neutral switch of the trans range
sensor refer to the transaxle section. Check for conti-
nuity to ground while the ignition switch is in the
start position and if equipped the clutch pedal
depressed. If not OK and the vehicle has an auto-
matic trans. verify Park Neutral switch operation. If
that checks OK check for continuity between PCM
and the terminal 86. Repair open circuit as required.
Also check the clutch interlock switch operation if
equipped with a manual transmission. If OK, the
PCM may be defective.
SAFETY SWITCHES
For diagnostics of the Transmission Range Sensor,
refer to the Transaxle section for more information. If equipped with Clutch Interlock/Upstop Switch,
refer to Diagnosis and Testing in the Clutch section.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to the Ignition Section
or Wiring Diagrams for more information. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
For battery diagnosis and testing, refer to the Bat-
tery section for procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Wiring Diagrams for more information.
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition and Fuel systems must be dis-
abled to prevent engine start while performing the
following tests.
(1) To disable the Ignition and Fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location. (2) Gain access to battery terminals.
(3) With all wiring harnesses and components
properly connected, perform the following: (a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp. Rotate and hold the
ignition switch in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between cable clamp and post. (b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp. Rotate and hold the igni-
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between the cable clamp and post. (c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
block near the battery cable attaching point.
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at ground cable attaching point. If
voltage reading is still above 0.2 volt after correct-
ing poor contacts, replace ground cable.
(4) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal. Hold the ignition switch key in
the START position. If voltage reads above 0.2 volt,
correct poor starter to engine ground. (a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid. Rotate and
hold the ignition switch in the START position. If
voltage reads above 0.2 volt, correct poor contact at
8Fs - 34 STARTINGRS
STARTING (Continued)

(2) Position the rear window defogger relay into
the proper receptacle in the IPM.
(3) Align the rear window defogger relay terminals
with the terminal cavities in the IPM receptacle.
(4) Push down firmly on the rear window defogger
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install the cover onto the IPM.
(6) Reconnect the battery negative cable.
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The rear window defogger switch is integrated into
the A/C-heater control mounted in the center of the
instrument panel (Fig. 5). The rear window defogger
switch and the rear window defogger LED indicator
cannot be repaired and, if faulty or damaged, the
A/C-heater control must be replaced.
OPERATION
An LED indicator will illuminate when the rear
window defogger switch is activated. The switch
energizes the A/C-heater control module which then
requests the front control module (FCM) to activate
the rear window defogger relay via the J1850 com-
munication bus. The rear window defogger relay con-
trols the current to flow to the grids of the rear
window defogger and the heated power side view
mirrors. The defogger relay will be on for approxi-
mately 10 minutes or until the control switch or igni-
tion is turned off.
REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE - GRID LINE AND
TERMINAL REPAIR
REAR WINDOW DEFOGGER GRID LINE REPAIR
WARNING: THE REPAIR KIT CONTAINS EPOXY
RESIN AND AMINE TYPE HARDENER WHICH MAY
CAUSE SKIN OR EYE IRRITATION AND CAN BE
HARMFUL IF SWALLOWED. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR OPEN
FLAME THE CONTENTS CONTAIN FLAMMABLE
SOLVENTS. KEEP OUT OF REACH OF CHILDREN.
²DO NOT TAKE INTERNALLY, IF SWALLOWED
INDUCE VOMITING AND CALL A PHYSICIAN IMME-
DIATELY.
²IF SKIN CONTACT OCCURS, WASH AFFECTED
AREAS WITH SOAP AND WATER.
²IF EYE CONTACT OCCURS, FLUSH WITH
PLENTY OF WATER.
The repair of the grid lines is possible using the
MopartGrid Line Repair Package or an equivalent.
(1) Mask the repair area so the conductive epoxy
can be extended onto the grid line(s) or the bus bar
(Fig. 6).
(2) Follow the instructions in the repair kit for
preparing the damaged area.
(3) Remove the package separator clamp and mix
the conductive epoxy thoroughly. Fold in half and cut
the center corner to dispense the epoxy.
(4) Apply the conductive epoxy through the slit in
the masking tape. Overlap both ends of the break(s)
by 19 mm (3/4 inch).
(5) Carefully remove the masking tape from the
grid line(s).
CAUTION: To prevent the glass from fracturing, do
not allow the glass surface to exceed 204É C (400É
F).
(6) Allow the epoxy to cure 24 hours at room tem-
perature or use a heat gun with a 260É to 371É C
(500É to 700É F) range for 15 minutes. Hold the heat
gun approximately 254 mm (10 inches) from the
repaired area.
(7) After the conductive epoxy is properly cured,
verify operation of the rear window defogger.
Fig. 5 A/C-Heater Control - Typical
1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH
5 - FRONT WINDOW DEFROSTER MODE SELECTOR
8G - 4 HEATED GLASSRS
REAR WINDOW DEFOGGER RELAY (Continued)

HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION..........................6OPERATION............................6
HEATED MIRRORS
DESCRIPTION
The optional heated mirror system only operates in
concert with the rear window defogger system, and
will be automatically shut off after a programmed
time interval of about ten minutes. After the initial
time interval has expired, if the defogger switch is
turned on again during the same ignition cycle, the
heated mirror system will automatically shut off
after about five minutes.
The heated mirror system will automatically shut
off if the ignition switch is turned to the Off position,
or it can be shut off manually by pressing the rear
window defogger switch a second time.
OPERATION
When the rear window defogger switch (Fig. 1) is
in the On position, an electric heater grid located
behind the glass of each of the outside rear view mir-
rors is energized. When energized, each of these
heater grids produce heat to help clear the outside
rear view mirrors of ice, snow, or fog.
The heated mirror system is controlled by a
momentary rear window defogger switch on the A/C-
heater control. An amber indicator lamp in the
switch will illuminate to indicate when the defogger
system is turned on.
If the outside mirror heating grids are both inoper-
ative, refer to DIAGNOSIS AND TESTING - REARWINDOW DEFOGGER SYSTEM in his group. If
only one of the outside mirror heating grids is inop-
erative, Refer to 8 - ELECTRICAL/POWER MIR-
RORS - DIAGNOSIS AND TESTING.
The heating grid behind each outside mirror glass
cannot be repaired and, if faulty or damaged, the
entire power mirror assembly must be replaced.
Fig. 1 A/C-Heater Control Panel
1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH
5 - FRONT WINDOW DEFROSTER MODE SELECTOR
8G - 6 HEATED MIRRORSRS

HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION..........................7
OPERATION............................8
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM.............................8
DRIVER HEATED SEAT SWITCH
DESCRIPTION..........................8
OPERATION............................8
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH.........................9
REMOVAL.............................10
INSTALLATION.........................10
HEATED SEAT ELEMENTS
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - HEATED SEAT
ELEMENTS..........................10REMOVAL.............................11
INSTALLATION.........................11
HEATED SEAT SENSOR
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR............................12
PASSENGER HEATED SEAT SWITCH
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - PASSENGER
HEATED SEAT SWITCH.................13
REMOVAL.............................14
INSTALLATION.........................14
HEATED SEAT SYSTEM
DESCRIPTION
Vehicles with the heated seat option can be visu-
ally identified by the two separate heated seatswitches located in the instrument panel center
stack, just above the radio (Fig. 1). The heated seat
system allows the front seat driver and passenger to
select from two different levels of supplemental elec-
trical seat heating (HI/LO), or no seat heating to suit
their individual comfort requirements. The heated
seat system for this vehicle includes the following
major components, which are described in further
detail later in this section:
²Heated Seat Elements- Four heated seat ele-
ments are used per vehicle, two for each front seat.
One heated seat element is integral to each front
seat trim cover, one in the seat back and one in the
seat bottom (cushion). Service replacement heating
elements are available, refer to heated seat elements
later in this section for additional information.
²Heated Seat Modules- Two heated seat mod-
ules are used per vehicle. One module is mounted to
each of the seat cushion pans, located under the for-
ward edge of each front seat. Refer to heated seat
module in the electronic control modules section of
the service manual for additional information.
²Heated Seat Sensors- Two heated seat sen-
sors are used per vehicle, one for each front seat. The
heated seat sensors are integral to each of the heated
seat bottoms (cushions).
²Heated Seat Switch- Two heated seat
switches are used per vehicle, one for the driver and
one for the passenger side front seats. The switches
are mounted in the instrument panel center stack.
Fig. 1 HEATED SEAT SWITCH LOCATIONS
1 - HEATED SEAT SWITCHES
RSHEATED SEAT SYSTEM8G-7