2005 CHRYSLER VOYAGER heating

(5) Install the upper radiator mounts to the cross-
member bolts, if removed. Tighten to 8 N´m (70 in.
lbs.).
(6) Install the radiator upper hose to the support
clip (2.4L engine).
RADIATOR FAN RELAY
DESCRIPTION
The radiator fan relay is a solid state type and is
located on the front bumper reinforcment (Fig. 21).
Refer to WIRING DIAGRAMS for a circuit sche-
matic.
OPERATION
The solid state radiator fan relay is controlled by
the Powertrain Control Module (PCM) by way of a
Pulse Width Modulated (PWM) signal. The relay con-
trol circuit supplies a 12 volt signal to the PCM. The
PCM then pulses the ground circuit to achieve fan on
time. The relay provides a voltage to the fan motors
which is proportional to the pulse width it receives
from the PCM. The duty cycle ranges from 30% for
low speed operation, then ramps-up to 100% for high
speed operation. This fan control system provides
infinitely variable fan speeds, allowing for improved
fan noise, A/C performance, better engine cooling,
and additional vehicle power.
To control operation of the relay, the PCM looks at
inputs from:
²Engine coolant temperature
²A/C pressure transducer
²Ambient temperature from the body controller
²Vehicle speed
²Transmission oil temperature
The PCM uses these inputs to determine when the
fan should operate and at what speed. For further
information on fan operation, (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - OPERATION).
REMOVAL
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the radiator crossmember to front fas-
cia closure panel.
(4) Disconnect the relay electrical connector (Fig.
21).
(5) Remove the rivet attaching the relay to the
front bumper beam (Fig. 21).
(6) Remove the relay.
INSTALLATION
CAUTION: The relay mounting location is designed
to dissipate heat. Ensure the relay is securely
attached to prevent relay ªthermalº shutdown and
relay damage, resulting in possible engine over-
heating.
(1) Position relay and install a new rivet (Fig. 21).
(2) Connect electrical connector to relay.
(3) Install closure panel and attaching screws.
(4) Connect negative cable to battery.
Fig. 21 Radiator Fan Relay
1 - FRONT FASCIA
2 - FAN RELAY
3 - RIVET
4 - A/C CONDENSER (FRONT SIDE)
RSENGINE7-31
RADIATOR FAN (Continued)

TRANSMISSION OIL COOLER
DESCRIPTION
The automatic transmission cooler is located in the
front of the radiator and behind the front fascia and
is conbined with the A/C condensor. The transmission
cooler is a heat exchanger that allows heat in the
transmission flud to be transferred to the air passing
over the cooler fins.
The Transmission oil cooler/A/C condenser assem-
blly is equipped with quick connect fitting for the
transmission oil cooler lines, a tapping block, for the
receiver/drier, and mounting provisions for the power
steering cooler.
The transmission oil cooler/AC condenser is ser-
viced as an assembly. For removal on vehicles
equipped with 2.4L/3.3L/3.8L engines, (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
CONDENSER - REMOVAL), vehicles equipped with2.5L/2.8L engines (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/A/C CONDENSER -
REMOVAL). For installation on vehicles equipped
with 2.4L/3.3L/3.8L engines (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C CON-
DENSER - INSTALLATION), and vehicles equipped
with 2.5L/2.8L engines (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/A/C CON-
DENSER - INSTALLATION).
INSPECTION
Inspect all hoses, tubes, clamps and connections for
leaks, cracks, or damage. Replace as necessary. Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
Inspect external coolers for leaks, loose mounts, or
damage. Replace as necessary.
TRANSMISSION OIL COOLER
LINES
REMOVAL
(1) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 3).
(2) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(3) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
Fig. 2 Oil Cooler Line Quick Connect Fitting -
Assembly
1 - QUICK CONNECT FITTING
2 - CLIP
3 - OIL COOLER LINE
4 - DUST CAP
Fig. 3 Radiator Sight Shield - Typical
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSTRANSMISSION7-39
TRANSMISSION (Continued)

²SCI Receive
²Speed Control
²Throttle Position Sensor
²Transmission Control Relay (Switched B+)
²Transmission Pressure Switches
²Transmission Temperature Sensor
²Transmission Input Shaft Speed Sensor
²Transmission Output Shaft Speed Sensor
²Transaxle Gear Engagement
²Vehicle Speed
NOTE: PCM Outputs:
²Air Conditioning Clutch Relay
²Automatic Shut Down (ASD) and Fuel Pump
Relays
²Data Link Connector (PCI and SCI Transmit)
²Double Start Override
²EGR Solenoid
²Fuel Injectors
²Generator Field
²High Speed Fan Relay
²Idle Air Control Motor
²Ignition Coils
²Leak Detection Pump
²Low Speed Fan Relay
²MTV Actuator
²Proportional Purge Solenoid
²SRV Valve
²Speed Control Relay
²Speed Control Vent Relay
²Speed Control Vacuum Relay
²8 Volt Output
²5 Volt Output
²Torque Reduction Request
²Transmission Control Relay
²Transmission Solenoids
²Vehicle Speed
Based on inputs it receives, the powertrain control
module (PCM) adjusts fuel injector pulse width, idle
speed, ignition timing, and canister purge operation.
The PCM regulates the cooling fans, air conditioning
and speed control systems. The PCM changes gener-
ator charge rate by adjusting the generator field.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
²Battery Voltage
²Intake Air Temperature Sensor
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Exhaust Gas Oxygen Content (heated oxygen
sensors)
²Manifold Absolute Pressure
²Throttle Position
The PCM adjusts engine idle speed through the
idle air control motor based on the following inputs.
²Brake Switch²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Park/Neutral
²Transaxle Gear Engagement
²Throttle Position
²Vehicle Speed
The PCM adjusts ignition timing based on the fol-
lowing inputs.
²Intake Air Temperature
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Knock Sensor
²Manifold Absolute Pressure
²Park/Neutral
²Transaxle Gear Engagement
²Throttle Position
The automatic shut down (ASD) and fuel pump
relays are mounted externally, but turned on and off
by the powertrain control module through the same
circuit.
The camshaft and crankshaft signals are sent to
the powertrain control module. If the PCM does not
receive both signals within approximately one second
of engine cranking, it deactivates the ASD and fuel
pump relays. When these relays are deactivated,
power is shut off to the fuel injectors, ignition coils,
fuel pump and the heating element in each oxygen
sensor.
The PCM contains a voltage converter that
changes battery voltage to a regulated 8.0 volts. The
8.0 volts power the camshaft position sensor, crank-
shaft position sensor and vehicle speed sensor. The
PCM also provides a 5.0 volts supply for the engine
coolant temperature sensor, intake air temperature
sensor, manifold absolute pressure sensor and throt-
tle position sensor.
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 in new PCM. Use
the DRBIIItscan tool to change the mileage in the
PCM. Refer to the appropriate Powertrain Diagnostic
Manual and the DRBIIItscan tool.
TRANSMISSION CONTROL
CLUTCH VOLUME INDEX (CVI)
An important function of the PCM is to monitor
Clutch Volume Index (CVI). CVIs represent the vol-
ume of fluid needed to compress a clutch pack.
The PCM monitors gear ratio changes by monitor-
ing the Input and Output Speed Sensors. The Input,
or Turbine Speed Sensor sends an electrical signal to
the PCM that represents input shaft rpm. The Out-
put Speed Sensor provides the PCM with output
shaft speed information.
8E - 12 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)

OPERATION
When the rear window defogger button is
depressed to the On position, current is directed to
the rear defogger grid lines and the heated power
mirrors (if equipped). The heated grid lines heat the
glass to help clear the rear window and side mirror
surfaces of fog or frost.
The electric backlight (EBL) system is controlled
by a momentary switch located in the A/C-heater
control on the instrument panel. A yellow indicator in
the switch will illuminate to indicate when the sys-
tem is turned on. The integrated power module (IPM)
contains the EBL system control circuitry.
NOTE: The rear window defogger turns off automat-
ically after approximately 10 minutes of initial oper-
ation. Each following activation cycle of the
defogger system will last approximately five min-
utes.
The EBL system will be automatically turned off
after a programmed time interval of about ten min-
utes. After the initial time interval has expired, if the
defogger switch is turned on again during the same
ignition cycle, the defogger system will automatically
turn off after about five minutes.
The EBL system will automatically shut off if the
ignition switch is turned to the Off position, or it can
be turned off manually by depressing the defogger
switch a second time.
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM
NOTE: Illumination of the defogger switch indicator
lamp means that there is electrical current available
at the output of the rear window defogger logic cir-
cuitry, but does not confirm that the electrical cur-
rent is reaching the rear glass heating grid lines.
NOTE: For circuit descriptions and diagrams of the
rear window defogger system, refer to 8W - WIRING
DIAGRAM INFORMATION.
Operation of the electrical backlight (EBL) system
can be confirmed by the following:(1) Turn the ignition switch to the On position. Set
the defogger switch in the On position. The rear win-
dow defogger operation can be checked by feeling the
rear window glass. A distinct difference in tempera-
ture between the grid lines and the adjacent clear
glass can be detected within three to four minutes of
operation.
(2) If a temperature difference is not detected, use
a 12-volt DC voltmeter and contact the rear glass
heating grid terminal B with the negative lead, and
terminal A with the positive lead (Fig. 2). The volt-
meter should read battery voltage. If the voltmeter
does not read battery voltage, check the following:
²Confirm that the ignition switch is in the On
position.
²Make sure that the rear glass heating grid feed
wire and ground wire are connected to the terminals.
Confirm that the ground wire has continuity to
ground.
²Check that fuse 13 (40 amp) in the integrated
power module (IPM) is OK. The fuse must be tight in
it's receptacle and all electrical connections must be
secure.
(3) When the above steps have been completed and
the rear glass heating grid is still inoperative, one or
more of the following is faulty. It may be necessary to
connect a DRBIIItscan tool to perform further diag-
nostics. Refer to Body Diagnostic Procedures.
²Rear window defogger switch in the A/C-heater
control.
²J1850 bus communication between the A/C-
heater control and the front control module (FCM).
²Rear window defogger (EBL) relay in the IPM.
²Rear window defogger (EBL) relay control circu-
ity in the IPM.
²Check for a loose wire connector or a wire
pushed out of a connector.
²Rear window grid lines (all grid lines would
have to be broken, or the power feed or ground wire
not connected, for the entire heating grid to be inop-
erative).
(4) If the system operation has been verified but
defogger switch LED indicator does not illuminate,
replace the A/C-heater control.
8G - 2 HEATED GLASSRS
HEATED GLASS (Continued)

(5) If broken defogger grid lines are suspected, use
a 12-volt DC voltmeter and contact terminal B with
the negative lead and each rear glass heating grid
line at it's mid-point with the positive lead. The volt-
meter should read approximately 6 volts at each grid
line mid-point C. If the voltmeter does not read
approximately 6 volts, repair the open grid line(s)
(Refer to 8 - ELECTRICAL/HEATED GLASS/REAR
WINDOW DEFOGGER GRID - STANDARD PROCE-
DURE).
REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The rear window defogger (EBL) relay (Fig. 3) is a
International Standards Organization (ISO)-type
relay. Relays conforming to the ISO specifications
have common physical dimensions, current capaci-
ties, terminal patterns, and terminal functions. The
rear window defogger relay is a electromechanical
device that switches battery current through a fuse
in the integrated power module (IPM) to the rear
window defogger grid and switches battery current
through a positive thermal coefficient (PTC) in the
IPM to the outside mirror heating grids. The relay isenergized when the relay coil is provided a ground
path by the rear window defogger relay control in the
front control module (FCM).
The rear window defogger (EBL) relay is located in
the IPM in the engine compartment. See the fuse
and relay layout map on the inner surface of the
cover of the IPM for rear window defogger relay iden-
tification and location.
The rear window defogger (EBL) relay cannot be
adjusted or repaired and, if damaged or faulty, it
must be replaced.
OPERATION
The ISO-standard rear window defogger (EBL)
relay consists of an electromagnetic coil, a resistor or
diode, and three (two fixed and one movable) electri-
cal contacts. The movable (common feed) relay con-
tact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.
Refer to the appropriate wiring information for
diagnosis and testing of the EBL relay and for com-
plete EBL system wiring diagrams.
Fig. 2 Grid Line Test
1 - VOLTMETER
2 - VOLTAGE FEED (A)
3 - FEED WIRE
4 - MID-POINT (C)
5 - HEATED WINDOW GRID
6 - GROUND WIRE
7 - GROUND (B)Fig. 3 Rear Window Defogger (EBL) Relay
RSHEATED GLASS8G-3
HEATED GLASS (Continued)

REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE
GRID REPAIR PROCEDURE
WARNING: Materials contained in the Repair Kit
(Part Number 04549275) may cause skin or eye irri-
tation. The kit contains epoxy resin and amine type
hardener, which are harmful if swallowed. Avoid
contact with the skin and eyes. For skin contact,
wash the affected areas with soap and water. For
contact with the eyes, flush with plenty of water. Do
not take internally. If taken internally, induce vomit-
ing and call a physician immediately. Use with ade-
quate ventilation. Do not use near fire or flame.
Contains flammable solvents. Keep out of the reach
of children. Failure to follow the warnings could
result in possible personal injury or death.
Repair of the rear glass heating grid lines, bus
bars or terminals can be accomplished using the
MopartRear Window Defogger Repair Kit (Part
Number 04549275) or equivalent.
(1) Mask the repair area with masking tape so
that the conductive epoxy can be applied neatly (Fig.
6). Extend the epoxy application onto the grid line or
the bus bar on each side of the break.
(2) Follow the instructions in the repair kit for
preparing the damaged area.
(3) Remove the package separator clamp and mix
the two conductive epoxy components thoroughly
within the packaging. Fold the package in half and
cut the center corner to dispense the epoxy.
(4) For grid line repairs, mask the area to be
repaired with masking tape or use a template.
(5) Apply the epoxy through the slit in the mask-
ing tape or template. Overlap both ends of the break
by at least 19 millimeters (0.75 inch).
(6) For a terminal replacement, mask the adjacent
areas so the epoxy can be extended onto the adjacent
grid line as well as the bus bar. Apply a thin layer of
epoxy to the area where the terminal was fastened
and onto the adjacent grid line.(7) Apply a thin layer of conductive epoxy to the
terminal and place it in the proper location on the
bus bar. To prevent the terminal from moving while
the epoxy is curing, it must be wedged or clamped.
(8) Carefully remove the masking tape or tem-
plate.
CAUTION: Do not allow the glass surface to exceed
204É C (400É F) when using a heat gun, or the glass
may fracture.
(9) Allow the epoxy to cure 24 hours at room tem-
perature, or carefully use a heat gun for fifteen min-
utes. When using a heat gun, hold it approximately
25.4 centimeters (10 inches) from the repair and do
not allow the glass surface to exceed 204É C (400É F).
NOTE: Do not attach the wire harness connectors
to the terminals until the curing process is com-
plete.
(10) After the conductive epoxy is properly cured,
remove the wedge or clamp from the terminal.
(11) Connect the wire harness leads to the grid
terminals and verify EBL operation.
Fig. 6 Grid Line Repair
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
RSHEATED GLASS8G-5

HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION..........................6OPERATION............................6
HEATED MIRRORS
DESCRIPTION
The optional heated mirror system is controlled by
the momentary rear window defogger switch which is
integral to the A/C-heater control (Fig. 1). An amber
indicator lamp in the switch will illuminate to indi-
cate when the rear window defogger (EBL) system is
turned on.
The heated mirror system only operates in concert
with the EBL system, and will be automatically shut
off after a programmed time interval of about 10
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 5 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 is pressed,
the rear window defogger (EBL) system becomes acti-
vated and an electric heater grid located behind the
glass of each of the outside rear view mirrors is ener-
gized. When energized, each of these heater grids
produce heat to help clear the outside rear view mir-
rors of ice, snow, or fog.If the outside mirror heating grids are both inoper-
ative, refer to DIAGNOSIS AND TESTING - REAR
WINDOW 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 - EBL/HEATED MIRROR SWITCH
5 - FRONT WINDOW DEFROSTER 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
HEATED SEAT SWITCH
DESCRIPTION..........................8
OPERATION............................9
DIAGNOSIS AND TESTING
DRIVER HEATED SEAT SWITCH..........9
REMOVAL.............................10
INSTALLATION.........................10HEATED SEAT ELEMENTS
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING
HEATED SEAT ELEMENTS..............11
REMOVAL.............................12
INSTALLATION.........................12
HEATED SEAT SENSOR
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING
HEATED SEAT SENSOR................13
HEATED SEAT SYSTEM
DESCRIPTION
Vehicles with the heated seat option can be visu-
ally identified by the two separate heated seat
switches 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:
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 8 - ELECTRICAL/
HEATED SEATS/HEATED SEAT ELEMENT -
DESCRIPTION) 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 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/
MEMORY HEATED SEAT/MIRROR MODULE -
DESCRIPTION) 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.
(Refer to 8 - ELECTRICAL/HEATED SEATS/
DRIVER HEATED SEAT SWITCH - DESCRIPTION)
for additional information.
Fig. 1 HEATED SEAT SWITCH LOCATIONS
1 - HEATED SEAT SWITCHES
RSHEATED SEAT SYSTEM8G-7