2005 CHRYSLER VOYAGER Page 61

AUDIO/VIDEO
TABLE OF CONTENTS
page page
AUDIO/VIDEO
DESCRIPTION..........................1
DIAGNOSIS AND TESTING
AUDIO/VIDEO.........................2
AMPLIFIER
REMOVAL.............................7
INSTALLATION..........................7
ANTENNA BODY AND CABLE
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING
ANTENNA BODY AND CABLE.............8
REMOVAL.............................8
INSTALLATION..........................8
ANTENNA MODULE - EXPORT
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING
ANTENNA MODULE - EXPORT...........10
REMOVAL.............................10
INSTALLATION.........................10
ANTENNA - NAVIGATION RADIO
REMOVAL.............................11
INSTALLATION.........................11
CD CHANGER
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11
DVD PLAYER
DESCRIPTION.........................12
REMOVAL.............................12
INSTALLATION.........................12
INSTRUMENT PANEL ANTENNA CABLE
REMOVAL.............................12INSTALLATION.........................12
QUARTER GLASS INTEGRAL ANTENNA -
EXPORT
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING
QUARTER GLASS INTEGRAL ANTENNA -
EXPORT............................13
RADIO
DESCRIPTION.........................13
OPERATION...........................14
DIAGNOSIS AND TESTING
RADIO..............................14
REMOVAL.............................14
INSTALLATION.........................15
RADIO NOISE SUPPRESSION COMPONENTS
DESCRIPTION.........................15
OPERATION...........................15
REMOTE SWITCHES
DESCRIPTION.........................16
OPERATION...........................16
DIAGNOSIS AND TESTING
REMOTE SWITCHES..................16
REMOVAL.............................17
INSTALLATION.........................17
SPEAKER
DIAGNOSIS AND TESTING
SPEAKER...........................18
REMOVAL.............................18
INSTALLATION.........................19
VIDEO SCREEN
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
AUDIO/VIDEO
DESCRIPTION
An audio system is standard on this model. A rear
seat video system is an available option. Several com-
binations of radio receivers are offered on this model.
The audio/video system uses an ignition switched
source of battery current so that the system will only
operate when the ignition switch is in the RUN or
ACCESSORY/ACCESSORY DELAY positions.
The audio system includes the following compo-
nents:²Amplifier
²Antenna
²CD changer (if equipped)
²DVD player (if equipped)
²Radio noise suppression components
²Radio receiver
²Speakers
²Video screen (if equipped)
Certain functions and features of the audio/video
system rely upon resources shared with other elec-
tronic modules in the vehicle over the Programmable
Communication Interface (PCI) bus network. The
data bus network allows the sharing of sensor infor-
RSAUDIO/VIDEO8A-1

CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME/BUZZER
DESCRIPTION..........................1
OPERATION............................1
WARNING.............................2
DIAGNOSIS AND TESTING - CHIME SYSTEM . . 2
PARK ASSIST DISPLAY
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4PARK ASSIST MODULE
DESCRIPTION..........................4
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
PARK ASSIST SENSOR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................6
CHIME/BUZZER
DESCRIPTION
The chime/buzzer system provides the driver with
warning chimes for:
²Seat Belt
²Exterior Lamps ON
²Key-In Ignition
²Engine Temperature Critical
²Turn Signals ON
²Dome Lamp ON
²Low Oil Pressure
²High Speed Warning
²Warning Lamp Announcement
²Key-In Accessory
²Low/High Tire Pressure
²Service Tire Pressure Monitor (TPM)
HIGH SPEED WARNING - EXPORT
The chime will sound, acting as a warning to the
driver that the vehicle speed has exceeded 120   3
Kp/h (75   2 mph).
Refer to the proper body diagnostic information
diagnosis and testing with a scan tool.
PARK ASSIST SYSTEM
The Park Assist System is an electronic parking
aid that alerts the driver to obstacles which are
located immediately behind the vehicle. Objects are
sensed using ultrasonic sound waves. When an object
is detected, the system will give the driver visual and
audible warnings. The system is customer program-
mable through the Electronic Vehicle Information
Center (EVIC) but will be enabled from the factory
as a default.
The major components of the park assist system
are:²Park Assist Module- supplies voltage to the
object detection sensors and park assist display. It
triggers the sensors, analyzes the echo delay times
and calculates obstacle distances. It sends display
information to the park assist display, performs sys-
tem diagnostics, and communicates via the Program-
mable Communication Interface (PCI) date bus
network.
²Park Assist Sensors- there are four sensors
located in the rear bumper that generate ultrasonic
pulses when triggered by the park assist module. The
sensors signal the park assist module when reflected
ultrasonic pulses are received.
²Park Assist Display- there are sixteen Light
Emitting Diode (LED) indicators which provide indi-
cation of relative distance to obstacles. When the sys-
tem is engaged and no obstacles are detected, the
two outermost yellow LED's are lit at reduced bright-
ness to show the system is working. As the distance
to a detected obstacle decreases, more yellow LED's
towards the center of the display illuminate.
For diagnosis and testing of the park assist sys-
tem, use a scan tool and the appropriate body diag-
nostic information.
OPERATION
Refer to the proper Body Diagnostic Procedures
manual for complete chime/buzzer operation and con-
ditions for operation.
HIGH SPEED WARNING - EXPORT
When the vehicle speed sensor sees 120   3 Km/h
(75   2 mph), it sends a PCI data bus message to the
Body Control Module (BCM). The BCM then turns on
the chime to let the driver know that the vehicle has
reached a speed greater than 120   3 Km/h (75   2
mph). This audible message will continue until the
vehicle is slowed below the predetermined speed.
RSCHIME/BUZZER8B-1

ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING.......................1
BODY CONTROL MODULE
DESCRIPTION..........................2
OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4
CONTROLLER ANTILOCK BRAKE
DESCRIPTION..........................4
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
DATA LINK CONNECTOR
DESCRIPTION..........................6
OPERATION............................6
FRONT CONTROL MODULE
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING
FRONT CONTROL MODULE..............7
REMOVAL.............................7
INSTALLATION..........................7
HEATED SEAT MODULE
DESCRIPTION..........................8
OPERATION............................8
DIAGNOSIS AND TESTING
HEATED SEAT MODULE.................9
REMOVAL.............................9
INSTALLATION..........................9
MEMORY SEAT/MIRROR MODULE
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING
MEMORY SEAT/MIRROR MODULE.........9
REMOVAL.............................10
INSTALLATION.........................10
POWER LIFTGATE CONTROL MODULE
DESCRIPTION.........................10OPERATION...........................10
DIAGNOSIS AND TESTING
POWER LIFTGATE CONTROL MODULE....10
REMOVAL.............................10
INSTALLATION.........................11
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION........................11
OPERATION - SENSOR RETURN - PCM
INPUT..............................14
OPERATION - DATA BUS COMMUNICATION
RECEIVE - PCM INPUT.................14
OPERATION - IGNITION SENSE - PCM
INPUT..............................14
OPERATION - PCM GROUND............14
OPERATION - 5 VOLT SUPPLY - PCM
OUTPUT............................15
STANDARD PROCEDURE
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES..........15
STANDARD PROCEDURE - PINION
FACTOR SETTING.....................15
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE........................15
REMOVAL
REMOVAL - SBEC CONTROLLER.........16
REMOVAL - NGC CONTROLLER..........16
INSTALLATION
INSTALLATION - SBEC CONTROLLER.....17
INSTALLATION.......................17
SLIDING DOOR CONTROL MODULE
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING
SLIDING DOOR CONTROL MODULE......18
REMOVAL.............................18
INSTALLATION.........................19
ELECTRONIC CONTROL
MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM for a failed driver,
control circuit or ground circuit, be sure to checkthe related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relay and sole-
noids) and shorted circuits (i.e. pull-ups, drivers
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one DTC has set.
RSELECTRONIC CONTROL MODULES8E-1

When a PCM (SBEC) and the SKIM are replaced
at the same time perform the following steps in
order:
(1) Program the new PCM (SBEC)
(2) Program the new SKIM
(3) Replace all ignition keys and program them to
the new SKIM.
PROGRAMMING THE PCM (SBEC)
The SKIS Secret Key is an ID code that is unique
to each SKIM. This code is programmed and stored
in the SKIM, PCM and transponder chip (ignition
keys). When replacing the PCM it is necessary to
program the secret key into the new PCM using the
DRB III. Perform the following steps to program the
secret key into the PCM.
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
(5) Select ENTER to update PCM VIN.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition to the RUN
position for one hour then enter the correct PIN.
(Ensure all accessories are turned off. Also monitor
the battery state and connect a battery charger if
necessary).
(6) Press ENTER to transfer the secret key (the
SKIM will send the secret key to the PCM).
(7) Press Page Back to get to the Select System
menu and select ENGINE, MISCELLANEOUS, and
SRI MEMORY CHECK.
(8) The DRB III will ask, Is odometer reading
between XX and XX? Select the YES or NO button on
the DRB III. If NO is selected, the DRB III will read,
Enter odometer Reading. Enter
the odometer reading from the Instrument Panel and
press ENTER.
PROGRAMMING THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Program the vehicle four-digit PIN into SKIM.
(5) Select COUNTRY CODE and enter the correct
country.NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, the SKIM must be replaced.
(6) Select YES to update VIN (the SKIM will learn
the VIN from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM will send the secret key to the SKIM).
(8) Program ignition keys to SKIM.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle keys will need to be replaced
and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PROGRAM IGNITION KEY'S.
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
If ignition key programming is unsuccessful, the
DRB III will display one of the following messages:
Programming Not Attempted - The DRB III
attempts to read the programmed key status and
there are no keys programmed into SKIM memory.
Programming Key Failed (Possible Used Key From
Wrong Vehicle) - SKIM is unable to program key due
to one of the following:
²faulty ignition key transponder
²ignition key is programmed to another vehicle.
8 Keys Already Learned, Programming Not Done -
SKIM transponder ID memory is full.
(5) Obtain ignition keys to be programmed from
customer (8 keys maximum).
(6) Using the DRB III, erase all ignition keys by
selecting MISCELLANEOUS and ERASE ALL CUR-
RENT IGN. KEYS.
(7) Program all ignition keys.
Learned Key In Ignition - Ignition key transponder
ID is currently programmed in SKIM memory.
BODY CONTROL MODULE
DESCRIPTION
The Body Control Module (BCM) is located in the
passenger compartment, attached to the bulkhead
underneath the left side of the instrument panel.
8E - 2 ELECTRONIC CONTROL MODULESRS
ELECTRONIC CONTROL MODULES (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

CHARGING
TABLE OF CONTENTS
page page
CHARGING
DESCRIPTION - CHARGING SYSTEM.......21
OPERATION - CHARGING SYSTEM.........21
DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTIC SYSTEM........22
SPECIFICATIONS
GENERATOR........................23
TORQUE............................23
SPECIFICATIONS - BATTERY
TEMPERATURE SENSOR...............23
SPECIAL TOOLS.......................24
BATTERY TEMPERATURE SENSOR
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................24
GENERATOR
DESCRIPTION.........................24
OPERATION...........................24REMOVAL
REMOVAL - 2.4L......................24
REMOVAL - 2.5L......................25
REMOVAL - 3.3/3.8L...................27
INSTALLATION
INSTALLATION - 2.4L..................27
INSTALLATION - 2.5L..................27
INSTALLATION - 3.3/3.8L................27
GENERATOR DECOUPLER PULLEY
DESCRIPTION.........................28
OPERATION...........................28
DIAGNOSIS AND TESTING - GENERATOR
DECOUPLER PULLEY..................28
REMOVAL.............................29
INSTALLATION.........................29
VOLTAGE REGULATOR
DESCRIPTION.........................30
OPERATION...........................30
CHARGING
DESCRIPTION - CHARGING SYSTEM
The charging system consists of:
²Generator
²Decoupler Pulley (If equipped)
²Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM)
²Ignition switch (refer to the Ignition System sec-
tion for information)
²Battery (refer to the Battery section for informa-
tion)
²Ambient Air Temperature (If equipped)
²Inlet Air Temperature (calculated battery tem-
perature)(If equipped)
²Voltmeter (refer to the Instrument Cluster sec-
tion for information if equipped)
²Wiring harness and connections (refer to the
Wiring section for information)
²Accessory drive belt (refer to the Cooling section
for more information)
²Battery Temperature sensor (if equipped)
OPERATION - CHARGING SYSTEM
The charging system is turned on and off with the
ignition switch. The system is on when the engine is
running and the ASD relay is energized. The ASD
relay is energized when the PCM grounds the ASD
control circuit. This voltage is connected through thePCM or IPM (intelligent power module) (if equipped)
and supplied to one of the generator field terminals
(Gen. Source +) at the back of the generator.
The generator is driven by the engine through a
serpentine belt and pulley or decoupler pulley
arrangement.
The amount of DC current produced by the gener-
ator is controlled by the EVR (field control) circuitry
contained within the PCM. This circuitry is con-
nected in series with the second rotor field terminal
and ground.
An Ambient air temperature sensor is used to cal-
culate the temperature near the battery. This tem-
perature data, along with data from monitored line
voltage (battery voltage sense circuit), is used by the
PCM to vary the battery charging rate. This is done
by cycling the ground path to control the strength of
the rotor magnetic field. The PCM then compensates
and regulates generator current output accordingly
to maintain system voltage at the targeted system
voltage based on battery temperature.
All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including EVR
(field control) circuitry, 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 certain failures it detects and
illuminate the (MIL) lamp. Refer to On-Board Diag-
nostics in the Electronic Control Modules(Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
RSCHARGING8F-21

STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION.........................31
OPERATION...........................31
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST.......................31
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST........................33
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST....................35
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST...............................36SPECIFICATIONS
Torques.............................36
STARTER ...........................37
STARTER MOTOR
REMOVAL
REMOVAL - 2.4L......................37
REMOVAL - 3.3/3.8L...................38
REMOVAL - 2.5L......................38
INSTALLATION
INSTALLATION - 2.4L..................39
INSTALLATION - 3.3/3.8L................39
INSTALLATION - 2.5L..................39
STARTING
DESCRIPTION
The starting system consists of:
²Starter relay
²Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
²Battery
²Battery cables
²Ignition switch and key lock cylinder
²Clutch pedal position switch (manual transmis-
sion)
²Park/neutral position switch (automatic trans-
mission)
²Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate in conjunction with one another, and must be
tested as a complete system. For correct operation of
starting/charging systems, all components used in
these 3 systems must perform within specifications.
When attempting to diagnose any of these systems, it
is important that you keep their interdependency in
mind.
The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Powertrain Control Mod-
ule (PCM). Use of an induction-type milliampere
ammeter, volt/ohmmeter, battery charger, carbon pile
rheostat (load tester), and 12-volt test lamp may be
required.
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
RSSTARTING8F-31

HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS........................... 1
HEATED MIRRORS......................... 6HEATED SEAT SYSTEM..................... 7
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM.....2
REAR WINDOW DEFOGGER RELAY
DESCRIPTION..........................3
OPERATION............................3REMOVAL.............................4
INSTALLATION..........................4
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION..........................4
OPERATION............................4
REAR WINDOW DEFOGGER GRID
STANDARD PROCEDURE
GRID REPAIR PROCEDURE..............5
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
The rear window defogger system, also known as
electrical backlight (EBL), consists of two vertical bus
bars linked by a series of grid lines fired onto the
inside surface of the rear window (Fig. 1).
The EBL system is turned ON or OFF by a control
switch located on the A/C-heater control at the center
of the instrument panel and by a rear window defog-
ger relay timing circuit integral to the integrated
power module (IPM) (Refer to 8 - ELECTRICAL/
HEATED GLASS/REAR WINDOW DEFOGGER
SWITCH - DESCRIPTION).
Circuit protection is provided by a 40 amp fuse
located in the IPM.
Fig. 1 Rear Window Defogger - Typical
1 - REAR DEFOGGER GRID
2 - REAR WINDOW
RSHEATED SYSTEMS8G-1