2005 CHRYSLER VOYAGER engine

(1) Plug the DRBIIItscan tool into the diagnostic
connector. The connector is located under the instru-
ment panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRBIIItto perform the Quick
Learn Procedure.
REMOVAL
REMOVAL - SBEC CONTROLLER
(1) Disconnect the negative battery cable.
(2) Remove the battery shield, refer to the Battery
section for more information.
(3) Remove the 2 upper PCM bracket bolts (Fig.
11).
(4) Remove the 2 PCM connectors.
(5) Remove the headlamp, refer to the Lamps sec-
tion for more information.
(6) Remove the lower PCM mounting bolt (Fig. 12).
(7) Remove PCM.
REMOVAL - NGC CONTROLLER
The PCM engine control strategy prevents reduced
idle speeds until after the engine operates for 320 km
(200 miles). If the PCM is replaced after 320 km (200
miles) of usage, update the mileage and vehicle iden-
tification number (VIN) in the new PCM. Use the
DRBIIItscan tool to change the millage and VIN in
the PCM. If this step is not done a Diagnostic Trou-
ble Code (DTC) may be set. Refer to the appropriate
Powertrain Diagnostic Manual and the DRBIIItscan
tool.
Fig. 11 PCM
1 - Attaching Bolts
Fig. 12 PCM LOWER BOLT
NGC CONTROLLER LOCATION
8E - 16 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)

(1) Turn wheels to the left.
(2) Disconnect the negative battery cable.
(3) Raise vehicle and support.
(4) Remove the left front wheel well splash shield
(Fig. 13).
(5) Unlock and disconnect the electrical connectors
(Fig. 14).
(6) Remove 3 screws from PCM to mounting
bracket.
(7) Remove the PCM.INSTALLATION
INSTALLATION - SBEC CONTROLLER
(1) Install the PCM.
(2) Install the lower PCM mounting bolt. Tighten
bolt.
(3) Install the 2 upper PCM bracket bolts. Tighten
bolt.
(4) Install the headlamp, refer to the Lamps sec-
tion for more information.
(5) Install the 2 PCM connectors.
(6) Install the battery shield, refer to the Battery
section for more information.
(7) Connect the negative battery cable.
INSTALLATION
The PCM engine control strategy prevents reduced
idle speeds until after the engine operates for 320 km
(200 miles). If the PCM is replaced after 320 km (200
miles) of usage, update the mileage and vehicle iden-
tification number (VIN) in the new PCM. Use the
DRBIIItscan tool to change the millage and VIN in
the PCM. If this step is not done a diagnostic trouble
code (DTC) may be set and SKIM must be done or
car will not start if it is a SKIM equipped car. If a
SKIM car you must do a secret key transfer also.
Refer to the appropriate Powertrain Diagnostic Man-
ual and the DRBIIItscan tool.
(1) Install PCM module to the mounting bracket.
(2) Install electrical connectors and lock.
(3) Install the splash shield.
(4) Lower vehicle.
(5) Connect the negative battery cable.
(6) Using DRBIIItscan tool, program mileage and
vehicle identification number (VIN) into PCM. Refer
to the DRBIIItscan tool and the appropriate Power-
train Diagnostic Manual.
Fig. 13 SPLASH SHIELD
Fig. 14 NGC CONTROLLER
RSELECTRONIC CONTROL MODULES8E-17
POWERTRAIN CONTROL MODULE (Continued)

ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 21STARTING............................... 31
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
BATTERY SYSTEM.....................2
CLEANING.............................5
INSPECTION...........................5
SPECIFICATIONS
BATTERY............................6
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS.......7
BATTERY
DESCRIPTION..........................7
OPERATION............................9
DIAGNOSIS AND TESTING
BATTERY............................9
STANDARD PROCEDURE
SPIRAL PLATE BATTERY CHARGING......10
CONVENTIONAL BATTERY CHARGING....11
OPEN-CIRCUIT VOLTAGE TEST..........13IGNITION-OFF DRAW TEST.............13
CHECKING BATTERY ELECTROLYTE
LEVEL..............................14
MICRO 420 BATTERY TESTER...........15
REMOVAL - BATTERY...................16
INSTALLATION.........................16
BATTERY HOLDDOWN
REMOVAL.............................16
INSTALLATION.........................16
BATTERY CABLES
DESCRIPTION.........................16
OPERATION...........................17
DIAGNOSIS AND TESTING
BATTERY CABLES....................17
REMOVAL.............................19
INSTALLATION.........................19
BATTERY TRAY
DESCRIPTION.........................19
REMOVAL.............................19
INSTALLATION.........................20
BATTERY SYSTEM
DESCRIPTION
This vehicle is equipped with a single 12-volt bat-
tery. All of the components of the battery system are
located within the engine compartment. The battery
system for this vehicle contains the following related
components:
²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Thermowrap- The battery thermow-
rap insulates the battery to protect it from engine
compartment temperature extremes.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
RSENGINE SYSTEMS8F-1

OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING
BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failuremust be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. (Refer to 8 -
ELECTRICAL/CHARGING - DIAGNOSIS AND
TESTING) for the proper charging system on-board
diagnostic test procedures.MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is
designed to help the dealership technicians diagnose
the cause of a defective battery. Follow the instruc-
tion manual supplied with the tester to properly
diagnose a vehicle. If the instruction manual is not
available refer to the standard procedure in this sec-
tion, which includes the directions for using the
Micro 420 battery tester.
8F - 2 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.1. The electrical system
ignition-off draw is excessive.1. (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE
- IGNITION-OFF DRAW TEST) for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
inoperative.2. Determine if the charging system is performing
to specifications. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND TESTING) for
additional charging system diagnosis and testing
procedures. Repair the inoperative charging
system, as required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the inoperative battery, as
required.
4. The battery terminal
connections are loose or
corroded.4. (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM/CABLES - DIAGNOSIS AND TESTING)
for the proper battery cable diagnosis and testing
procedures. Clean and tighten the battery
terminal connections, as required.
5. The battery has an
incorrect size or rating for
this vehicle.5. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
- SPECIFICATIONS) for the proper size and
rating. Replace an incorrect battery, as required.
6. The battery is inoperative. 6. Test the battery using the Micro 420 battery
tester. Refer to the Standard Procedures in this
section for additional test procedures. Replace
the inoperative battery, as required.
7. The starting system is
inoperative.7. Determine if the starting system is performing
to specifications. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND TESTING) for the
proper starting system diagnosis and testing
procedures. Repair the inoperative starting
system, as required.
8. The battery is physically
damaged.8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
RSBATTERY SYSTEM8F-3
BATTERY SYSTEM (Continued)

(5) Inspect the battery built-in test indicator sight
glass (if equipped) for an indication of the battery
condition. If the battery is discharged, charge as
required. (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE - BAT-
TERY CHARGING) for the proper battery charging
procedures.
SPECIFICATIONS
BATTERY
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity(RC) rating or Ampere-Hours (AH) rating can be
found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
²Group Size- The outside dimensions and ter-
minal placement of the battery conform to standards
established by the Battery Council International
(BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
ment.
²Cold Cranking Amperage- The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
rent (in amperes) the battery can deliver for thirty
seconds at -18É C (0É F). Terminal voltage must not
fall below 7.2 volts during or after the thirty second
discharge period. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements.
²Reserve Capacity- The Reserve Capacity (RC)
rating specifies the time (in minutes) it takes for bat-
tery terminal voltage to fall below 10.5 volts, at a
discharge rate of 25 amperes. RC is determined with
the battery fully-charged at 26.7É C (80É F). This rat-
ing estimates how long the battery might last after a
charging system failure, under minimum electrical
load.
²Ampere-Hours- The Ampere-Hours (AH) rat-
ing specifies the current (in amperes) that a battery
can deliver steadily for twenty hours, with the volt-
age in the battery not falling below 10.5 volts. This
rating is also sometimes identified as the twenty-
hour discharge rating.
BATTERY CLASSIFICATIONS & RATINGS
Part NumberBCI Group Size
ClassificationCold Cranking
AmperageReserve
CapacityAmpere -
HoursLoad Test
Amperage
4686158AD 34 500 110 Minutes 60 250
4727159AD 34 600 120 Minutes 66 300
4727242AD DIN H6 600 120 Minutes 66 300
4868999AA 34 700 90 Minutes 50 350
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
8F - 6 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)

SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
There are three different batteries available for
this vehicle. Vehicles equipped with a diesel engine
utilize a spiral wound plate designed battery with
recombination technology. This is a maintenance-free
battery that is capable of delivering more power than
a conventional battery. This additional power is
required by a diesel engine during cold cranking.
Vehicles equipped with a gasoline engine utilize a
conventional battery. Refer to the following informa-
tion for detailed differences and descriptions of these
batteries.
SPIRAL PLATE BATTERY - DIESEL ENGINE
By tightly winding layers of spiral grids and acid-
permeated vitreous separators into cells, the battery
has more power and service life than conventional
batteries of the same size. The spiral plate battery is
permanently sealed. Through gas recombination,
hydrogen and oxygen within the battery are captured
during normal charging and reunited to form thewater within the electrolyte, eliminating the need to
add distilled water. Therefore, these batteries have
non-removable battery vent caps (Fig. 4).
The acid inside a spiral plate battery is bound
within the vitreous separators, ending the threat of
acid leaks. This feature allows the battery to be
installed in any position anywhere in the vehicle.
Spiral plate technology is the process by which the
plates holding the active material in the battery are
wound tightly in coils instead of hanging flat, like
conventional batteries. This design has a lower inter-
nal resistance and also increases the active material
surface area.
WARNING: NEVER EXCEED 14.4 VOLTS WHEN
CHARGING A SPIRAL PLATE BATTERY. PERSONAL
INJURY AND/OR BATTERY DAMAGE MAY RESULT.
Due to the maintanance-free design, distilled water
cannot be added to this battery. Therefore, if more
than 14.4 volts are used during the spiral plate bat-
tery charging process, water vapor can be exhausted
through the pressure-sensitive battery vents and lost
for good. This can permanently damage the spiral
plate battery.
Micro 420 Battery Tester
Fig. 4 MAINTENANCE-FREE DIESEL ENGINE
BATTERY
RSBATTERY SYSTEM8F-7
BATTERY SYSTEM (Continued)

CONVENTIONAL BATTERY - GASOLINE ENGINE
Low-maintenance batteriesare used on export
vehicles equipped with a gasoline engine, these bat-
teries have removable battery cell caps (Fig. 5).
Watercanbe added to this battery. Under normal
service, the composition of this battery reduces gas-
sing and water loss at normal charge rates. However
these batteries may require additional distilled water
after years of service.
Maintenance-free batteriesare standard facto-
ry-installed equipment on all domestic vehicles. Male
post type terminals made of a soft lead material pro-
trude from the top of the molded plastic battery case
(Fig. 6)to provide the means for connecting the bat-
tery to the vehicle electrical system. The battery pos-
itive terminal post is visibly larger in diameter than
the negative terminal post, for easy identification.
The lettersPOSandNEGare also molded into the
top of the battery case adjacent to their respective
positive and negative terminal posts for additional
identification confirmation.
This battery is designed to provide a safe, efficient
and reliable means of storing electrical energy in a
chemical form. This means of energy storage allows
the battery to produce the electrical energy required
to operate the engine starting system, as well as to
operate many of the other vehicle accessory systems
for limited durations while the engine and/or thecharging system are not operating. The battery is
made up of six individual cells that are connected in
series. Each cell contains positively charged plate
groups that are connected with lead straps to the
positive terminal post, and negatively charged plate
groups that are connected with lead straps to the
negative terminal post. Each plate consists of a stiff
mesh framework or grid coated with lead dioxide
(positive plate) or sponge lead (negative plate). Insu-
lators or plate separators made of a non-conductive
material are inserted between the positive and nega-
tive plates to prevent them from contacting or short-
ing against one another. These dissimilar metal
plates are submerged in a sulfuric acid and water
solution called an electrolyte.
Some factory-installed batteries have a built-in test
indicator (hydrometer). The color visible in the sight
glass of the indicator will reveal the battery condi-
tion. For more information on the use of the built-in
test indicator, refer toStandard Procedures. The
chemical composition of the metal coated plates
within the low-maintenance battery used in export
models reduces battery gassing and water loss at
normal charge and discharge rates. Therefore, the
battery should not require additional water in nor-
mal service. If the electrolyte level in this battery
does become low, distilled water must be added. How-
ever, rapid loss of electrolyte can be caused by an
overcharging condition. Be certain to diagnose the
charging system after replenishing the water in the
Fig. 5 BATTERY CELL CAP REMOVAL/
INSTALLATION - LOW-MAINTANANCE GASOLINE
ENGINE BATTERY - EXPORT
1 - BATTERY CELL CAP
2 - BATTERY CASE
Fig. 6 Maintenance-Free Battery - Domestic
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - VENT
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - INDICATOR EYE (if equipped)
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - MAINTENANCE-FREE BATTERY
8F - 8 BATTERY SYSTEMRS
BATTERY (Continued)