2005 CHRYSLER VOYAGER Module

CONDITION POSSIBLE CAUSES CORRECTION
Inoperative motor assembly Refer to the appropriate diagnostic
information.
Inoperative full open switch Refer to the appropriate diagnostic
information.
Binding or sticking of components Establish location of binding and replace
components as necessary
Power loss during Liftgate
operationLow battery voltage Charge battery
Inoperative Power Liftgate Module or
BCMDisconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative motor assembly Check for no drive condition
No power latching in
primary and/or secondary
positionsInoperative latch assembly Check for blown fuse and loose wiring
connections
Check for foreign matter preventing the
operation of latch assembly
Refer to the appropriate diagnostic
information. Replace latch assembly as
necessary
Binding or sticking of components Establish location of binding and replace
components as necessary
Inoperative Power Liftgate or BCM Disconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter or other possible obstruction
Inoperative motor assembly Check for no drive condition
Latch will not fully release
from primary positionInoperative latch assembly Check for blown fuse and loose wiring
connections
Check for foreign matter or damaged
components preventing the operation of
latch assembly
Refer to the appropriate diagnostic
information. Replace latch assembly as
necessary
Inoperative outside handle switch Refer to the appropriate diagnostic
information. Replace switch as necessary
RSPOWER LIFTGATE SYSTEM8N-5
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Inoperative Power Liftgate Module or
BCMDisconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Binding or sticking of components Establish location of binding and replace
components as necessary
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
Inoperative latch assembly Check for foreign matter preventing the
operation of latch assembly
Check wire connection
Pawl and/or ratchet switch inoperative.
Replace latch as necessary
Inoperative BCM Check electrical connections
Refer to the appropriate diagnostic
information for additional checks
Replace BCM as necessary
Inoperative key fob Verify inoperative key fob by trying other
key fob functions
Replace key fob battery
Reprogram key fob
Replace key fob as necessary
Inoperative Power Liftgate Module Disconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative liftgate motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections
Motor clutch does not engage. Replace
liftgate motor assembly
Full open switch inoperative, replace switch
as necessary
Liftgate does not stay open Inoperative liftgate prop rods Check for broken attachments. Replace
prop rods as necessary
High inside/outside opening
effortInoperative liftgate prop rods Check for broken attachments. Replace
prop rods as necessary
8N - 6 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Gear motor did not disengage Refer to the appropriate diagnostic
information. Replace components as
necessary
Binding or sticking of components Establish location of binding and replace
components as necessary
Liftgate continues to cinch
closed during power modeInoperative latch assembly Check for blown fuse and loose wiring
connections
Check for foreign matter preventing the
operation of latch assembly
Refer to the appropriate diagnostic
information. Replace components as
necessary
Inoperative Power Liftgate Module or
BCMDisconnect then reconnect battery to reset
module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Liftgate continues to open
during power mode
(runaway motor)Inoperative Power Liftgate Module or
BCMDisconnect then reconnect the battery
negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative full open switch Check wire connections
Replace switch, if necessary
Inoperative motor assembly Check for continuous drive condition
Liftgate opens very slowly Inoperative liftgate motor assembly Check wire connections
Replace motor assembly as necessary
Inoperative liftgate prop rods Replace prop rods as necessary
Binding or sticking of components Establish location of binding and replace
components as necessary
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 as
necessary
RSPOWER LIFTGATE SYSTEM8N-7
POWER LIFTGATE SYSTEM (Continued)

STANDARD PROCEDURE
LIFTGATE ADJUSTMENT
In order for the power liftgate system to function
properly the liftgate must move freely and smoothly.
The power liftgate system can accommodate for some
minor changes in the effort required to move the lift-
gate. However, in extreme conditions the liftgate may
need to be mechanically adjusted for proper fit and
finish. (Refer to 23 - BODY/DECKLID/HATCH/LIFT-
GATE/TAILGATE/LIFTGATE - INSTALLATION) for
detailed instructions.
If a problem exists with the power liftgate and it is
suspected to be extreme effort, check the liftgate prop
rods and hinges for free movement.
NOTE: Routine application of Mopar MP-50Tor
equivalent on the chrome prop rod shafts and lift-
gate latch and hinges will help keep the liftgate in
good working order.
POWER LIFTGATE LEARN CYCLE
Any time a power liftgate component is removed,
replaced or a liftgate adjustment is performed a learn
cycle must be performed. This learn cycle enables the
power liftgate control module to learn or relearn
information (travel limits, resistance to door travel,
etc.) which allows it to perform properly and safely.
Perform the following to complete a power liftgate
learn cycle:
(1) Obtain a DRBIIIt, or equivalent scan tool.
(2) Connect the scan tool to the vehicle and check
for any power liftgate system stored Diagnostic Trou-
ble Codes (DTCs), correct and erase any stored
DTCs.
(3) Using the scan tool, Go into Test Routine Menu
and select the power open command.
(4) Select the power close command.
(5) The liftgate learn cycle is complete.
If a DRBIIItor equivalent scan tool is not avail-
able, the learn cycle can be performed by actuating
the liftgate using any of the normal command
switches. Be certain to cycle the liftgate through a
complete open and close cycle before returning the
vehicle to service.
NOTE: If the power liftgate will not complete a full
cycle a problem exists with the power liftgate sys-
tem. (Refer to 8 - ELECTRICAL/POWER DOORS -
DIAGNOSIS AND TESTING).
CHIME/THERMISTOR
DESCRIPTION
The chime/thermistor assembly is a small capacitor
shaped electrical component mounted to the rear
license plate lamp housing assembly (Fig. 2) , located
just above the license plate. The chime portion of the
assembly controls the audible chime sound heard at
the rear of the vehicle when the power liftgate is in
motion. The thermistor portion of the assembly is a
temperature sensor, used by the power liftgate con-
trol module. The chime/thermistor assembly is a ser-
viceable component.
OPERATION
The chime/thermistor assembly performs two dif-
ferent functions for the power liftgate system. First,
the chime portion provides an audible chime sound
which is controlled by the power liftgate control mod-
ule. The chime/thermistor assembly is hardwired to
the power liftgate control module. Second the ther-
mistor provides a outside temperature reading by
way of a resistance reading supplied to the power
liftgate control module. As temperature increases the
resistance reading increases, as temperature
decreases the resistance reading decreases.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 2 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
8N - 8 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

(2) Remove the rear light bar assembly from the
vehicle. (Refer to 8 - ELECTRICAL/POWER DOORS/
SWITCH - REMOVAL) for the procedure.
(3) Grasp the light bar at its sides next to ther-
mistor/chime assembly and gently pull the two sides
of the light bar apart until the thermistor/chime
assembly can be removed.
INSTALLATION
(1) Gently pull the two sides of the light bar apart
until the thermistor/chime assembly can be installed.
(2) Install the rear light bar assembly on the vehi-
cle. (Refer to 8 - ELECTRICAL/POWER DOORS/
SWITCH - INSTALLATION) for the procedure.
(3) Connect the battery negative cable.
ENGAGE ACTUATOR
DESCRIPTION
The 12 volt engage actuator (Fig. 3) provides the
engagement and disengagement of the liftgate gear
motor to the lift gear by way of an over center link,
activated by a lever.
The engage actuator is a serviceable component
and cannot be repaired, if found to be inoperative it
must be replaced.
OPERATION
The engage actuators normal position is disen-
gaged. When a power liftgate open or close command
is generated from any of the command switches, the
power liftgate control module signals the engage
actuator to move its lever to the engaged position.
This engages the gear motor to the lift gear, so when
the motor turns the lift gate moves upward or down-
wards depending on its current position.
During a manual liftgate open or close cycle the
engage actuator is disengaged, allowing unrestricted
liftgate movement.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left rear D-pillar trim from the
vehicle, (Refer to 23 - BODY/INTERIOR/LEFT
D-PILLAR TRIM PANEL - REMOVAL).
(3) Manually engage the actuator link rod, this
must be done to access one of the engage actuator
retaining screws.
(4) Remove the two engage actuator retaining
screws (Fig. 4).
(5) Disconnect the engage actuator electrical con-
nector and remove the engage actuator from the
vehicle.
Fig. 3 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 4 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
RSPOWER LIFTGATE SYSTEM8N-9
CHIME/THERMISTOR (Continued)

INSTALLATION
(1) Position the engage actuator in the vehicle and
connect the engage actuator electrical connector.
(2) Install the two engage actuator retaining
screws.
(3) Manually disengage the actuator.
(4) Install the left rear D-pillar trim on the vehi-
cle, (Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and engage actua-
tor operation. Cycle the power liftgate through one
complete open and close cycle.
EXTERIOR HANDLE SWITCH
DESCRIPTION
The exterior handle switch is an electronic release
switch mounted to the rear license plate lamp hous-
ing assembly, located just above the license plate.
This switch controls the power liftgate release func-
tion and is also capable of reversing the power lift-
gate when it is in motion. A full power open cycle
cannot be performed using this switch, only one of
the power open command switches (key fob and over-
head console mounted) can be used to perform a full
power open cycle. The exterior handle switch is a ser-
viceable component.
OPERATION
When the exterior handle switch is depressed, with
the liftgate in the closed position, a message is sent
to the Body Control Module (BCM). The BCM then
sends a signal to the power liftgate control module
via the Programmable Communication Interface
(PCI) data bus circuit. The power liftgate control
module then sends a signal to the power latch
mounted actuator, which moves the liftgate from the
primary closed and latched position to the open and
movable position. If the liftgate is not pulled open
once the latch releases within a few seconds, the
latch will cinch closed again.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open the liftgate and remove the liftgate trim
panel, (Refer to 23 - BODY/DECKLID/HATCH/LIFT-
GATE/TAILGATE/TRIM PANEL - REMOVAL).
(3) Remove the rear lamp bar assembly from the
vehicle.(4) Locate the two wires going to the exterior han-
dle switch. Cut the tie strap and trace the wires to
the large electrical connector and back the wires out
of the large connector and through the grommet.
Take care to mark the location of the wire ter-
minals in relation to the large connector so
that they are positioned in the appropriate cav-
ities upon switch installation.
(5) Depress the two exterior handle switch retain-
ing tabs and roll the switch out of the light bar
assembly (Fig. 5).
INSTALLATION
(1) Install the handle switch in the light bar
assembly (Fig. 6).
(2) Locate the two wires going to the exterior han-
dle switch. Install the wires through the grommet
and in the large connector. Secure with a tie strap.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the handle switch. Refer to the appropriate
wiring information for complete circuit schematic or
connector pin-out information.
(3) Install the rear light bar.
(4) Install the liftgate trim panel, (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
Fig. 5 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
8N - 10 POWER LIFTGATE SYSTEMRS
ENGAGE ACTUATOR (Continued)

(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate through one com-
plete open and close cycle, this will allow the power
liftgate control module to relearn its cycle with the
new components.
FULL OPEN SWITCH
DESCRIPTION
The full open switch is located on the gear motor
housing (Fig. 7) and is used to signal the power lift-
gate control module when the power liftgate is in the
full open position. Two wires are used from the full
open switch contacts to the gear motor assemblies
main electrical connector. The full open switch is a
serviceable component.
OPERATION
When the power liftgate reaches the full open posi-
tion, the gear motor housing mounted full open
switch electrical contacts close. This sends a ground
signal to the power liftgate control module, telling
the module that the liftgate has reached the full open
position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the battery negative cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(6) Verify power liftgate system and full open
switch operation. Cycle the power liftgate through
one complete open and close cycle, this will allow the
power liftgate control module to relearn its cycle with
the new components.
Fig. 6 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 7 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
RSPOWER LIFTGATE SYSTEM8N-11
EXTERIOR HANDLE SWITCH (Continued)

INSTALLATION
(1) Position the power latch in the vehicle.
(2) Connect the liftgate lock cylinder link rod (Fig.
10) on the cinch latch assembly. Rotate the plastic
retaining clip 90 É to lock retaining clip onto the link
rod.
(3) Connect the link rod on the lock cylinder.
(4) Install three new power latch retaining bolts.
Torque to 10 N´m (90 in. lbs.).
(5) Connect the power latch electrical connector
and secure push pin retainers.
(6) Connect the battery negative cable.
(7) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the power latch.
(8) Verify power liftgate system and power cinch /
release latch operation. Cycle the power liftgate
through one complete open and close cycle, this will
allow the power liftgate control module to relearn its
cycle with the new components.
(9) Verify power liftgate manual operation. Using
liftgate key rotate the lock cylinder to verify door
operation. Pull door open using exterior liftgate han-
dle / switch.
(10) Install the liftgate trim panel, (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - INSTALLATION).
LATCH ACTUATOR
DESCRIPTION
The power cinch and/or power release latch (Fig.
11) is made possible by a latch actuator attached to
the leading edge of the power latch assembly. This 12
volt latch actuator contains a small drive gear that
meshes with the latch assemblies internal gears to
perform the power cinch close / power release opera-
tions. (Refer to 8 - ELECTRICAL/POWER DOORS/
LATCH - DESCRIPTION) for additional information.
The power cinch/release actuator is serviceable com-
ponent.
OPERATION
During a power close cycle, the power cinch actua-
tor provides the torque required to close the power
liftgate from the secondary to the primary closed and
latched position. During a power open cycle, the
power release actuator releases the liftgate from the
primary closed and latched position to the fully
unlatched and movable position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 10 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
Fig. 11 POWER LATCH ORIENTATION
1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
RSPOWER LIFTGATE SYSTEM8N-13
LATCH (Continued)